Finite element simulation of residual stress of wire arc additive manufactured low alloy high strength steel component assisted by interlayer hammering
Restricted accessResearch articleFirst published online October, 2023
Finite element simulation of residual stress of wire arc additive manufactured low alloy high strength steel component assisted by interlayer hammering
Residual stress is an important factor affecting structural deformation, which seriously reduces the dimensional accuracy, fatigue strength, and safety of structural parts. In this study, a coupled thermal-mechanical finite element model for wire arc additive manufacturing (WAAM) was established based on ABAQUS and Fortran subroutine and the accuracy of the simulation results was verified by experiments. The effects of hammering and hammering temperature on the residual stress in low alloy high strength (HSLA) steel built by the WAAM process were analyzed. The results showed that the effect of reducing the residual stress increased and then decreased with the hammer temperature in the hammer temperature range of this study. The optimal hammer temperature was found to be 800 °C. The maximum longitudinal, transverse, and Z-direction residual stress of the deposited wall after 800 °C interlayer hammering decreased by 20.7, 273.9, and 116.9 MPa, respectively.
ChioccaAFrendoFAielloF, et al.Influence of residual stresses on the fatigue life of welded joints. Numerical simulation and experimental tests. Int J Fatigue2022; 162: 106901.
2.
SuominenLKhurshidMParantainenJ. Residual stresses in welded components following post-weld treatment methods. Procedia Eng2013; 66: 181–191.
3.
WilliamsSWMartinaFAddisonAC, et al.Wire+arc additive manufacturing. Mater Sci Technol2016; 32: 641–647.
4.
KarayelEBozkurtY. Additive manufacturing method and different welding applications. J. Mater Res Technol2020; 9: 11424–11438.
5.
KumarNBhavsarHMaheshPVS, et al.Wire arc additive manufacturing-a revolutionary method in additive manufacturing. Mater Chem Phys2022; 285: 126144.
6.
SrivastavaMRatheeSTiwariA, et al.Wire arc additive manufacturing of metals: a review on processes, materials and their behaviour. Mater Chem Phys2023; 294: 126988.
7.
TomarBShivaSNathT. A review on wire arc additive manufacturing: processing parameters, defects, quality improvement and recent advances. Mater Today Commun2022; 31: 103739.
8.
XiongJLeiYYLiR. Finite element analysis and experimental validation of thermal behavior for thin-walled parts in GMAW-based additive manufacturing with various base plate preheating temperatures. Appl Therm Eng2017; 126: 43–52.
9.
SinghCPSarmaRKapilS. The qualitative analysis of warpage on residual stresses in wire arc additive manufacturing. Mater Today Proc2022; 62: 6619–6627.
10.
LiRXiongJLeiYY. Investigation on thermal stress evolution induced by wire and arc additive manufacturing for circular thin-walled parts. J Manuf Process2019; 40: 59–67.
11.
YangYBZhouXLiQ, et al.A computationally efficient thermo-mechanical model for wire arc additive manufacturing. Addit Manuf2021; 46: 102090.
12.
LefebvreFRevilla-GomezCBuffiereJY, et al.Understanding the mechanisms responsible for the beneficial effect of hammer peening in welded structure under fatigue loading. Adv Mat Res2014; 996: 761–768.
HaciniLLêNVBocherP. Effect of impact energy on residual stresses induced by hammer peening of 304L plates. J Mater Process Tech2008; 208: 542–548.
15.
FangXWZhangLJChenGP, et al.Microstructure evolution of wire-arc additively manufactured 2319 aluminum alloy with interlayer hammering. Mater Sci Eng A2021; 800: 140168.
16.
ZhouSYWangJYYangG, et al.Periodic microstructure of Al–Mg alloy fabricated by inter-layer hammering hybrid wire arc additive manufacturing: formation mechanism, microstructural and mechanical characterization. Mater Sci Eng A2022; 860: 144314.
17.
XiongXCQinXPJiFL, et al.Microstructure and mechanical properties of wire+arc additively manufactured mild steel by welding with trailing hammer peening. Steel Res Int2021; 92: 2100238.
18.
ZouZDWangXHQuSY, et al.Numerical analysis of elimination of welding residual stress in white cast iron by hammer treatment. J Shandong Univ Technol1999; 29: 201–205.
19.
BaptistaRInfanteVBrancoC. Fully dynamic numerical simulation of the hammer peening fatigue life improvement technique. Procedia Eng2011; 10: 1943–1948.
20.
QuanGZZhaoJLuS, et al.Study on distribution of residual stress of single-pass wire arc additive manufacturing and elimination of stress by hammering. J Plast Eng2020; 27: 115–124.
21.
ZouZDWangXHQuSY. The numerical simulation of the peening effect on welding residual stress. China Mech Eng1999; 10: 466–468.
22.
LiSLMaYJWangDY, et al.Influence of welding with trailing peening on welding stress based on electromagnetism control. Weld Technol2008; 37: 66–68.
TengTLFungCPChangPH, et al.Analysis of residual stresses and distortions in t-joint fillet welds. Int J Press Vessels Pip2001; 78: 523–538.
25.
TengTLChangPHTsengWC. Effect of welding sequences on residual stresses. Comput Struct2003; 81: 273–286.
26.
ZhangYXFangCYanH. Simulation study on the deflection response of the 921A steel thin plate under explosive impact load. IOP Conf Ser: Mater Sci Eng2018; 322: 022054.
27.
ChiumentiMCerveraMSalmiA, et al.Finite element modeling of multi-pass welding and shaped metal deposition processes. Comput Methods Appl Mech Eng2010; 199: 2343–2359.
28.
DingDHZhangSMLuQH, et al.The well-distributed volumetric heat source model for numerical simulation of wire arc additive manufacturing process. Mater Today Commun2021; 27: 102430.
29.
ZubairuddinMAlbertSKVasudevanM, et al.Numerical simulation of multi-pass GTA welding of grade 91 steel. J Manuf Process2017; 27: 87–97.
30.
DengDMurakawaH. Numerical simulation of temperature field and residual stress in multi-pass welds in stainless steel pipe and comparison with experimental measurements. Comput Mater Sci2006; 37: 269–277.
