Localized material compression to correct distortion in wire arc additive manufacturing
Wire Arc Additive Manufacturing (WAAM) is an advanced manufacturing technology which utilizes welding systems to generate three dimensional geometries in a layer-by-layer fashion. Distortion or warping of a print substrate and WAAM components due to thermally induced residual stresses is an ongoing...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-07-01
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| Series: | Additive Manufacturing Letters |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S277236902500043X |
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| _version_ | 1849232618845896704 |
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| author | Nathan Lambert Shramana Ghosh Randall Lind Michael Sebok Andrzej Nycz Whitney Watters Chris Masuo Yukinori Yamamoto |
| author_facet | Nathan Lambert Shramana Ghosh Randall Lind Michael Sebok Andrzej Nycz Whitney Watters Chris Masuo Yukinori Yamamoto |
| author_sort | Nathan Lambert |
| collection | DOAJ |
| description | Wire Arc Additive Manufacturing (WAAM) is an advanced manufacturing technology which utilizes welding systems to generate three dimensional geometries in a layer-by-layer fashion. Distortion or warping of a print substrate and WAAM components due to thermally induced residual stresses is an ongoing challenge limiting the widespread adoption of WAAM technologies for producing components. In this manuscript, a novel approach is described to address thermal distortion in deposited components by applying lateral compressions along the length of the deposited material. To demonstrate this method, a series of single-track walls were printed and compressed at evenly spaced intervals using a modified hydraulic cutter tool. The jaws of the tool were modified to compress material rather than to shear it. A mathematical model was developed to relate the curvature of the deposited material to the volume of compression required to eliminate this distortion. Validation of this model was performed using 3D scan data to compare the change in wall curvature induced by compression to the volume of the applied compressions. Substrate deflection was also compared against a control wall, and implementation of wall compression reduced maximum deflections by 93% across a series of four depositions and subsequent compressions. Wall cross sections were also analyzed to determine the impact of compression on material hardness and grain structure. The results demonstrate that successively placed lateral compressions can effectively control and potentially eliminate bending distortion in printed parts. This methodology can be further developed to form a robust model for correction of thermally-induced distortion in WAAM components. |
| format | Article |
| id | doaj-art-5edf483a9fa143fb852da4a2f483b87c |
| institution | Kabale University |
| issn | 2772-3690 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Additive Manufacturing Letters |
| spelling | doaj-art-5edf483a9fa143fb852da4a2f483b87c2025-08-21T04:17:56ZengElsevierAdditive Manufacturing Letters2772-36902025-07-011410031010.1016/j.addlet.2025.100310Localized material compression to correct distortion in wire arc additive manufacturingNathan Lambert0Shramana Ghosh1Randall Lind2Michael Sebok3Andrzej Nycz4Whitney Watters5Chris Masuo6Yukinori Yamamoto7Corresponding author.; Manufacturing Science Division, Oak Ridge National Laboratory, Oak Ridge, TN 37830, United StatesManufacturing Science Division, Oak Ridge National Laboratory, Oak Ridge, TN 37830, United StatesManufacturing Science Division, Oak Ridge National Laboratory, Oak Ridge, TN 37830, United StatesManufacturing Science Division, Oak Ridge National Laboratory, Oak Ridge, TN 37830, United StatesManufacturing Science Division, Oak Ridge National Laboratory, Oak Ridge, TN 37830, United StatesManufacturing Science Division, Oak Ridge National Laboratory, Oak Ridge, TN 37830, United StatesManufacturing Science Division, Oak Ridge National Laboratory, Oak Ridge, TN 37830, United StatesManufacturing Science Division, Oak Ridge National Laboratory, Oak Ridge, TN 37830, United StatesWire Arc Additive Manufacturing (WAAM) is an advanced manufacturing technology which utilizes welding systems to generate three dimensional geometries in a layer-by-layer fashion. Distortion or warping of a print substrate and WAAM components due to thermally induced residual stresses is an ongoing challenge limiting the widespread adoption of WAAM technologies for producing components. In this manuscript, a novel approach is described to address thermal distortion in deposited components by applying lateral compressions along the length of the deposited material. To demonstrate this method, a series of single-track walls were printed and compressed at evenly spaced intervals using a modified hydraulic cutter tool. The jaws of the tool were modified to compress material rather than to shear it. A mathematical model was developed to relate the curvature of the deposited material to the volume of compression required to eliminate this distortion. Validation of this model was performed using 3D scan data to compare the change in wall curvature induced by compression to the volume of the applied compressions. Substrate deflection was also compared against a control wall, and implementation of wall compression reduced maximum deflections by 93% across a series of four depositions and subsequent compressions. Wall cross sections were also analyzed to determine the impact of compression on material hardness and grain structure. The results demonstrate that successively placed lateral compressions can effectively control and potentially eliminate bending distortion in printed parts. This methodology can be further developed to form a robust model for correction of thermally-induced distortion in WAAM components.http://www.sciencedirect.com/science/article/pii/S277236902500043XAdditive manufacturingWire arc additive manufacturingDistortionLateral compression |
| spellingShingle | Nathan Lambert Shramana Ghosh Randall Lind Michael Sebok Andrzej Nycz Whitney Watters Chris Masuo Yukinori Yamamoto Localized material compression to correct distortion in wire arc additive manufacturing Additive Manufacturing Letters Additive manufacturing Wire arc additive manufacturing Distortion Lateral compression |
| title | Localized material compression to correct distortion in wire arc additive manufacturing |
| title_full | Localized material compression to correct distortion in wire arc additive manufacturing |
| title_fullStr | Localized material compression to correct distortion in wire arc additive manufacturing |
| title_full_unstemmed | Localized material compression to correct distortion in wire arc additive manufacturing |
| title_short | Localized material compression to correct distortion in wire arc additive manufacturing |
| title_sort | localized material compression to correct distortion in wire arc additive manufacturing |
| topic | Additive manufacturing Wire arc additive manufacturing Distortion Lateral compression |
| url | http://www.sciencedirect.com/science/article/pii/S277236902500043X |
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