Integration of tube end forming in wire arc additive manufacturing: An experimental and numerical investigation

Integration of tube end forming operations in metal additive manufacturing routes has a great potential for the fabrication customized features additively deposited hollow parts. This paper is focused on integration expansion with rigid tapered conical mandrels to highlight advantages construction overhanging flares derived from elimination support structures and prevention humping. The work draws mechanical formability characterization stainless steel AISI 316L tubes produced by wire arc (WAAM) experimental numerical simulation expansion. Strain loading paths obtained digital image correlation finite element analysis combined strain values at onset necking fracture allow determining critical ductile damage that can safely withstand. Results show despite being influenced dendritic based microstructure, their performance adequate operations, such as expansion, be successfully integrated without need using expensive hardware complex deposition strategies.