Numerical Modeling of Distortions and Residual Stresses During Wire Arc Additive Manufacturing of an ER 5183 Alloy with Weaving Deposition

Abstract This study deals with the numerical modelling of residual stresses and distortions occurring during wire arc additive manufacturing of ER 5183 parts with weaving deposition. It is shown that the mesh size, as well as the accurate implementation of the heat source weaving pattern has a significant impact on the results. The mechanical material properties for the simulation are evaluated utilizing in-house standardized test equipment. Validation of the thermo-mechanical simulation is done by monitoring temperatures and distortions during the process. Additionally, 3D scans of the part geometry and residual stress measurements using the hole drilling method are conducted post manufacturing. A good agreement between the experimental measurements and the numerical simulation results is found with the use of an accurate heat source model.