A Finite Element Analysis on the Effect of Scanning Pattern and Energy on Residual Stress and Deformation in Wire Arc...

Wire arc additive manufacturing (WAAM) is a metal additive manufacturing (AM) technique that has a high throughput and has seen a potential interest for replacing currently available subtractive manufacturing techniques. Contrary to other metal AM machines, WAAM rigs can be built using existing welding plants and using welding wire as feedstock, thus, making it a cheap and viable manufacturing technique for a number of industries, such as the maritime industry. However, the effects of AM parameters, such as the scanning pattern and energy, on the residual stress and deformation, are still not completely understood. In this work, a finite element (FE) study has been conducted to understand the influence of different scanning patterns (alternate, in-out, raster and zigzag) and energies on residual stress and warpage. Analyses show that the in-out scanning pattern leads to the highest residual stress, while the zigzag pattern results in the lowest residual stress for all scanning energies considered in this study. Findings in the present study also show that the scanning pattern affects the residual stress and deformation more than does the scanning energy.