Printed metallic parts often suffer from thermomechanical defects such as delamination, buckling and warping, and this effect is exacerbated in multi-arc additive manufacturing (AM) due to the extensive heat input and large molten pool. These defects originate primarily because of high residual stresses accumulated during layer-by-layer deposition. Here we develop, validate and employ a three-dimensional finite element model with two independent heat sources to analyse the thermomechanical responses in dual-arc parallel AM of Ti6Al4V thin-walled parts. The results are compared with those of the conventional single-arc AM. Although the deformation in dual-arc AM is slightly larger than that in single-arc AM, the stresses at the substrate-deposit interface for dual-arc AM are reduced by 53% due to the lower cooling rate.
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