Residual stresses in thin walled-structures manufactured by directed energy deposition: In-situ measurements, fast thermo-mechanical simulation and buckling

Manufacturing strains and subsequent residual stresses are key elements in the behavior of thin-walled structures, as they induce buckling, warping, failure. This work proposes a combined experimental numerical analysis these features by investigating additive manufacturing structure using directed energy deposition. In-situ measurements temperature plan displacement fields during fabrication identified over entire part all along process infrared optical cameras. One novelty this is to determine field without stopping unlike most existing approaches, which significantly simplifies monitoring process. In addition, modeling has been developed investigate formation stresses. proposed approach reach reasonably short computation time, decoupling thermal mechanical problems, interesting for parametric studies. Results relevant, computed good agreement with in-situ measurements. A complementary buckling also shows ability model predict when be stopped due excessive out deflection. The presented can therefore used tool select suitable parameters given part.