Modelling and optimising hybrid process of wire arc additive manufacturing and high-pressure rolling

• Inter-layer, stacked-layers and post-build rolling is modelled to investigate their interaction with wire arc additive manufacturing (WAAM) for mitigating WAAM residual stress distortion. Difference in mitigation efficacy of using flat roller slotted demonstrated explained. Influence depth cyclic deposition alter plastic strain that causes determined analysed different process conditions. Hybrid can be optimised through changing the number layers each cycle modifying geometry. high-pressure build large-scale components low detrimental (RS) We developed an efficient coupled model a steel wall simulate between rolling. The predicted RS distributions dimensions agree well experimental results. Cyclic variation longitudinal tensile occurs during inter-layer clamped condition. influence characterised by underlying are plastically deformed after cycle. For roller, has smaller than deposition; consequently, does not eliminate but rather contains regeneration thermal cycles. Rolling introduces more thereby effectively reduces unclamping Compared rolling, stacked-four-layer larger hence achieves similar fewer operations, while lower due insufficient penetration. Therefore, recommended optimal hybrid