Efficient determination and evaluation of steady-state thermal–mechanical variables generated by wire arc additive manufacturing and high pressure rolling

Abstract Wire arc additive manufacturing (WAAM) of large component is susceptible to residual stress (RS) and distortion, which are detrimental need be mitigated through high pressure rolling or other methods. In this study, an efficient modelling approach developed simulate both WAAM rolling, can also applied processes determine steady-state variables. For a clamped wall component, the computationally reduced-size models (i.e. short models) obtain solutions equivalent those obtained by conventional full-size models. models, undesirable effect reducing length modelled counteracted imposing additional longitudinal constraint as proper specific processes. The solution model in condition then mapped long for analysis RS distortion after removal clamps. predictions temperature, good agreement with experimental measurements. region deposited wall, compressive plastic strain (PS) approximately uniformly formed, influential factors implications PS analysed. on deposition introduces tensile that compensates induced deposition, thereby mitigating alleviating bending This study demonstrates large-scale provides insights into strains stresses generated rolling.