Shekhar Srivastava

Department of Industrial
and Production Engineering, Distribution of Residual Stress in
Wire-Arc Additively Manufactured
Dr. B R Ambedkar National
Institute of Technology,

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Jalandhar, Punjab 144011, India

Small-Scale Component: Single-

e-mail: shekhars.ip.17@nitj.ac.in

Rajiv Kumar Garg

Department of Industrial
and Production Engineering,
Dr. B R Ambedkar National
Institute of Technology,
Jalandhar, Punjab 144011, India
e-mail: gargrk@nitj.ac.in
Anish Sachdeva
Department of Industrial
and Production Engineering,
Dr. B R Ambedkar National
Institute of Technology,
Jalandhar, Punjab 144011, India
e-mail: asachdeva@nitj.ac.in
Vishal S. Sharma
Department of Industrial and Production
Engineering,
Dr B R Ambedkar National
Institute of Technology,
Jalandhar, Punjab 144011, India;
School of Mechanical, Industrial and
Aeronautical Engineering,
University of Witwatersrand,
Johannesburg 2050, South Africa
e-mail: sharmavs@nitj.ac.in
Versus Multi-Level Heat Input
Accumulated heat input during layer deposition causes high residual stress in the Wire-Arc
Additive Manufacturing (WAAM) components. The developed residual stress results in
defects like distortion, delamination, cracks, and low fatigue life. To deal with such engi-
neering problems, numerical methods have always been required. It gives an insight into
the system that can be used for real-world applications. Consequently, a sequentially
coupled finite element model has been developed to simulate the thermal–structural beha-
vior of the feedstock during and after deposition in the WAAM process. Precisely, a novel
multi-level layer-wise heat input approach characterized by four different stages is com-
pared with the layer-wise single heat input strategy. The variation of thermal and residual
stress distributions has been studied based on the different cases proposed related to layer-
wise multi-level heat loading. A good agreement between predicted and experimentally
observed temperature and residual stress values has been observed. The developed frame-
work predicted thermal distribution with an average error of 9.71%, 9.13%, 7.57%, and
4.52% for case #1, case #2, case #3, and case #4, respectively. In addition to that, longitu-
dinal stresses in the modeled component recorded a reduction of 17.94% for four-level heat
input (case #4) compared to the respective value observed in case #1. Therefore, a multi-
level heat input strategy is recommended over a single-level heat input approach for the
components with small deposition lengths manufactured through the WAAM process.
[DOI: 10.1115/1.4055569]
Keywords: metal additive manufacturing, FEM, residual stress, thermomechanical model,
distortion, heat input, design for manufacturing, modeling and simulation

1 Introduction the synonyms of WAAM [13]. Initially, Chin et al. [14,15] performed
thermomechanical modeling for solid freeform fabrication to study
Wire-based Directed Energy Deposition Additive Manufacturing
the effect of droplet deposition to form a column and a layer in two
(DED-AM) process is a promising technique in metal-based Addi-
different studies, respectively. Jandric and Kovacevic [12] performed
tive Manufacturing (AM) processes. A variant of DED-AM process
a heat management study based on the FEM procedure and proposed
with an arc welding-based heat input and a continuously fed metal
a real-time adaptive controller of the welding parameters for the solid
wire is called Wire Arc Additive Manufacturing (WAAM). The
freeform fabrication process. Mughal et al. [1] proposed a three-
WAAM process acquires a high deposition rate and low cost for
dimensional (3D) finite element procedure to model weld-based
fabricating a large-sized component with less or moderate complex-
rapid prototyping process and deduced that the thermal evolution
ity in the geometry [1]. However, the deposited component through
during deposition is the main reason for developed deformation and
the WAAM process may experience acute residual stress and distor-
residual stress. From the early 2000s, the modeling and experimental
tion due to accumulated heat input during deposition. The continu-
approaches have been practiced to develop the WAAM process.
ous heat input and the developed residual stress cause various
Table 1 summarizes a few explored simulation and experimental
complications in the component, i.e., distortion [2], cracks [3,4],
frameworks applied to the WAAM process to date.
high surface roughness [5], increased fatigue failure [6], and
The reviewed articles collectively provide useful insight into the
stress corrosion cracking [7]. A useful engineering tool, i.e.,
development of the WAAM process. Seemingly, an experimental
Finite Element Method (FEM), has been utilized to study the
method can control residual stress in the samples fabricated
effect of heat evolution on the developed residual stress [8]. One
through the WAAM process. However, it needs a different frame-
can perform FEM-based thermomechanical modeling to observe
work for different materials, which incurs a huge cost in
transient thermal and stress distributions in any engineering appli-
hit-and-trial experimentation. In contrast, Wu et al. [27] suggested
cation subjected to heat and mechanical loading [9]. Therefore, it
that controlling a few influential parameters (the gap between the
has been extended for the exploration of parametric variation on
solidus and preheat temperatures, the product of elastic modulus
various responses (i.e., transient temperature and residual stress distri-
and the coefficient of thermal expansion, molten pool volume, sub-
bution) in shaped deposition manufacturing [10], layered manufactur-
strate rigidity, and heat input) can reduce defects in the WAAM
ing [11], solid freeform fabrication process [12], and weld-based
process. They emphasized investigating these parameters through
rapid prototyping [1]. The above-given manufacturing processes are
numerical and machine learning modeling approaches to save a
considerable cost required in hit-and-trial experimentation.
Corresponding author.
Further, a prior knowledge of the growth pattern and the magni-
Manuscript received May 31, 2022; final manuscript received September 1, 2022; tude of residual stress is a must concerning the safety aspect of part
published online September 30, 2022. Assoc. Editor: Jingjing Li. design for WAAM fabricated components [28]. Generally, during

Journal of Manufacturing Science and Engineering FEBRUARY 2023, Vol. 145 / 021008-1
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