Influence of the WAAM process and design aspects on residual stresses in high-strength structural steels

Abstract Wire arc additive manufacturing (WAAM) enables the efficient production of weight-optimized modern engineering structures. Further increases in efficiency can be achieved by using high-strength structural steels. Commercial welding consumables for WAAM are already available on market. Lack knowledge and guidelines regarding residual stress component safety during operation leads to severely limited use industry applications. The sensitive microstructure steels carries a high risk cold cracking; therefore, stresses play crucial role. For this reason, influences material, process, design formation cracking being investigated. material used has yield strength over 800 MPa. This is adjusted via solid solution strengthening martensitic phase transformation. volume expansion associated with martensite significant influence stresses. focus present investigation parameters their hardness stresses, which analyzed means X-ray diffraction (XRD). Reference specimens (hollow cuboids) welded fully automated systematic variation heat control design. Welding AM geometry correlated resulting microstructure, hardness, state. Increased input lower tensile causes unfavorable mechanical properties. affects dissipation conditions intensity restraint stress.