Influence of Overloading on Residual Stress Distribution in Surface-Treated Wire Arc Additive-Manufactured Steel...

Area of Science:

• Materials Science and Engineering
• Mechanical Engineering
• Renewable Energy Systems

Background:

• The global push for decarbonization necessitates advancements in Offshore Renewable Energy (ORE).
• Wire Arc Additive Manufacturing (WAAM) presents a promising, cost-effective solution for ORE component production and repair, alleviating supply chain constraints.
• However, WAAM components in offshore environments face cyclic loading, making fatigue performance and residual stress management critical for operational integrity.

Purpose of the Study:

• To evaluate the influence of fatigue overloading on residual stress distribution in surface-treated WAAM specimens.
• To explore the effectiveness of laser shock peening and rolling post-processing techniques on the fatigue behavior of WAAM components.
• To ensure the reliability and safety of WAAM-manufactured components for offshore renewable energy applications.

Main Methods:

• Utilized Compact Tension (CT) specimens manufactured using Wire Arc Additive Manufacturing (WAAM).
• Applied surface treatments, specifically laser shock peening and rolling, to induce compressive residual stresses.
• Investigated fatigue cracking behavior and analyzed residual stress distribution under fatigue overloading conditions.

Main Results:

• Surface treatments (laser shock peening and rolling) were effective in introducing compressive residual stresses.
• Fatigue overloading was found to influence the residual stress distribution within the WAAM specimens.
• The study provides insights into the fatigue performance enhancement offered by post-processing techniques.

Conclusions:

• Surface treatments are crucial for mitigating residual stresses and improving fatigue life in WAAM components for ORE.
• Understanding the interaction between fatigue loading and residual stresses is vital for predicting component lifespan.
• This research supports the wider adoption of WAAM in the offshore renewable energy sector by addressing critical material performance concerns.