Residual stress accumulation in large-scale Ti-6Al-4V wire-arc additive manufacturing

Ritin Mathews; Jaydeep Karandikar; Christopher Tyler; Scott Smith

doi:10.1016/j.procir.2023.09.247

Residual stress accumulation in large-scale Ti-6Al-4V wire-arc additive manufacturing

Ritin Mathews, Jaydeep Karandikar, Christopher Tyler, Scott Smith

Research output: Contribution to journal › Conference article › peer-review

3 Scopus citations

Abstract

Large-scale additive manufacturing (AM) is of interest in the manufacturing industry to produce components of dimensions on the order of hundreds of millimeters to meters in scale. Wire-arc AM (WAAM) of Ti-6Al-4V (Ti64) is an attractive technique for large-scale AM in the aerospace industry, give the high strength-to-weight ratio of the material and high deposition rate of the process. However, due to the large scale, significant distortion and residual stresses are developed in the material during deposition and cooling, potentially leading to part failure. WAAM of a prototypical large-scale Ti64 machine tool component is studied in this work via finite element analysis (FEA). Element activation/deactivation technique is employed to simulate deposition and the resulting distortion and residual stress (RS) predictions are analyzed to evaluate the possibility of crack formation. Significant distortion (∼10 mm) and RS (>1300 MPa) is predicted, suggesting the formation of cracks and possible crack propagation into the build region. Incorporation of fillets significantly reduces RS concentration regions, thus reducing the possibility of part failure. Material deposition sequence also affects the RS pattern in the build.

Original language	English
Pages (from-to)	180-185
Number of pages	6
Journal	Procedia CIRP
Volume	121
DOIs	https://doi.org/10.1016/j.procir.2023.09.247
State	Published - 2024
Event	11th CIRP Global Web Conference, CIRPe 2023 - Virtual, Online Duration: Oct 24 2023 → Oct 26 2023

Funding

∗ Corresponding author. E-mail address: [email protected] This manuscript has been authored by UT-Battelle, LLC, under contract DE-AC05-00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). The authors gratefully acknowledge the support of the DOD, Industrial Base Analysis and Sustainment program.

Keywords

Distortion
Residual stress
Stress-induced cracking
Wire-arc additive manufacturing

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1016/j.procir.2023.09.247

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title = "Residual stress accumulation in large-scale Ti-6Al-4V wire-arc additive manufacturing",

abstract = "Large-scale additive manufacturing (AM) is of interest in the manufacturing industry to produce components of dimensions on the order of hundreds of millimeters to meters in scale. Wire-arc AM (WAAM) of Ti-6Al-4V (Ti64) is an attractive technique for large-scale AM in the aerospace industry, give the high strength-to-weight ratio of the material and high deposition rate of the process. However, due to the large scale, significant distortion and residual stresses are developed in the material during deposition and cooling, potentially leading to part failure. WAAM of a prototypical large-scale Ti64 machine tool component is studied in this work via finite element analysis (FEA). Element activation/deactivation technique is employed to simulate deposition and the resulting distortion and residual stress (RS) predictions are analyzed to evaluate the possibility of crack formation. Significant distortion (∼10 mm) and RS (>1300 MPa) is predicted, suggesting the formation of cracks and possible crack propagation into the build region. Incorporation of fillets significantly reduces RS concentration regions, thus reducing the possibility of part failure. Material deposition sequence also affects the RS pattern in the build.",

keywords = "Distortion, Residual stress, Stress-induced cracking, Wire-arc additive manufacturing",

author = "Ritin Mathews and Jaydeep Karandikar and Christopher Tyler and Scott Smith",

note = "Publisher Copyright: {\textcopyright} 2023 The Authors. Published by Elsevier B.V.; 11th CIRP Global Web Conference, CIRPe 2023 ; Conference date: 24-10-2023 Through 26-10-2023",

year = "2024",

doi = "10.1016/j.procir.2023.09.247",

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AU - Mathews, Ritin

AU - Karandikar, Jaydeep

AU - Tyler, Christopher

AU - Smith, Scott

PY - 2024

Y1 - 2024

N2 - Large-scale additive manufacturing (AM) is of interest in the manufacturing industry to produce components of dimensions on the order of hundreds of millimeters to meters in scale. Wire-arc AM (WAAM) of Ti-6Al-4V (Ti64) is an attractive technique for large-scale AM in the aerospace industry, give the high strength-to-weight ratio of the material and high deposition rate of the process. However, due to the large scale, significant distortion and residual stresses are developed in the material during deposition and cooling, potentially leading to part failure. WAAM of a prototypical large-scale Ti64 machine tool component is studied in this work via finite element analysis (FEA). Element activation/deactivation technique is employed to simulate deposition and the resulting distortion and residual stress (RS) predictions are analyzed to evaluate the possibility of crack formation. Significant distortion (∼10 mm) and RS (>1300 MPa) is predicted, suggesting the formation of cracks and possible crack propagation into the build region. Incorporation of fillets significantly reduces RS concentration regions, thus reducing the possibility of part failure. Material deposition sequence also affects the RS pattern in the build.

AB - Large-scale additive manufacturing (AM) is of interest in the manufacturing industry to produce components of dimensions on the order of hundreds of millimeters to meters in scale. Wire-arc AM (WAAM) of Ti-6Al-4V (Ti64) is an attractive technique for large-scale AM in the aerospace industry, give the high strength-to-weight ratio of the material and high deposition rate of the process. However, due to the large scale, significant distortion and residual stresses are developed in the material during deposition and cooling, potentially leading to part failure. WAAM of a prototypical large-scale Ti64 machine tool component is studied in this work via finite element analysis (FEA). Element activation/deactivation technique is employed to simulate deposition and the resulting distortion and residual stress (RS) predictions are analyzed to evaluate the possibility of crack formation. Significant distortion (∼10 mm) and RS (>1300 MPa) is predicted, suggesting the formation of cracks and possible crack propagation into the build region. Incorporation of fillets significantly reduces RS concentration regions, thus reducing the possibility of part failure. Material deposition sequence also affects the RS pattern in the build.

KW - Distortion

KW - Residual stress

KW - Stress-induced cracking

KW - Wire-arc additive manufacturing

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DO - 10.1016/j.procir.2023.09.247

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SN - 2212-8271

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JO - Procedia CIRP

JF - Procedia CIRP

T2 - 11th CIRP Global Web Conference, CIRPe 2023

Y2 - 24 October 2023 through 26 October 2023

ER -

Residual stress accumulation in large-scale Ti-6Al-4V wire-arc additive manufacturing

Abstract

Funding

Keywords

UN SDGs

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