Understanding and designing post-build rolling for mitigation of residual stress and distortion in wire arc additively manufactured components

Post-build rolling can mitigate residual stress (RS) and distortion in large-scale components built by wire arc additive manufacturing (WAAM). In this study, based on numerical simulations that considered both WAAM deposition vertical rolling, the mechanisms of rolling-enabled mitigation RS a WAAM-built steel wall are elucidated. The influences process configuration condition, such as roller design (flat, profiled slotted rollers), load (25–75 kN) roller-to-wall friction coefficient (0–0.8) distributions plastic strain (PS) were investigated. It is found most effective to introduce tensile PS for counteracting compressive generated deposition, thereby reducing clamped condition final after removal clamps. Higher increases rolling-induced PS, which leads more extensive WAAM-generated RS. also demonstrate significantly affects when employed. However, efficacy flat/profiled insensitive coefficient. This study could underpin development an optimal post-build efficient components.