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Effect of Phase Transformations on Scanning Strategy in WAAM Fabrication.

Muhammad Hassaan Ali1, You Sung Han1

  • 1Department of Mechatronics Engineering, Incheon National University, 119 Academy-ro, Yeonsu-gu, Incheon 22012, Korea.

Materials (Basel, Switzerland)
|December 24, 2021
PubMed
Summary

Wire arc additive manufacturing (WAAM) scan strategies impact residual stress and distortion. Discontinuous patterns like alternate line scanning minimize these issues, offering more consistent results for martensitic steels.

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Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Computational Mechanics

Background:

  • Wire Arc Additive Manufacturing (WAAM) offers high production rates and low costs.
  • Residual stress and part distortion are significant challenges hindering WAAM adoption.
  • Scan strategies influence thermal history, impacting residual stresses and distortion.

Purpose of the Study:

  • To investigate the effect of phase transformations on residual stresses and distortion in WAAM parts.
  • To analyze how different scan strategies influence these effects.
  • To provide insights for optimizing WAAM processes for low-carbon martensitic steels.

Main Methods:

  • Finite Element Method (FEM) simulations were employed.
  • Phase transformation effects were considered in the simulations.
Keywords:
finite element analysisphase transformationthe scanning patterntransformation plasticitywire arc additive manufacturing

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  • Various deposition patterns (discontinuous and continuous) were analyzed.

    • Main Results:

    • Phase transformations had minimal impact on residual stresses for discontinuous patterns (alternate, raster).
    • Phase transformations significantly affected residual stresses in continuous patterns (zigzag, in-out, out-in).
    • Accurate simulation of complex patterns requires considering phase transformations due to their influence on temperature history.

    Conclusions:

    • Discontinuous line scanning patterns are recommended for uniform residual stress and distortion in WAAM.
    • The alternate line pattern demonstrated the most consistent performance overall.
    • Scan strategy selection is crucial for mitigating residual stress and distortion in WAAM of martensitic steels.