Process Modelling and Defect Prediction for Wire

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Wire + Arc Additive Manufacture (WAAM) is a process for building large scale metallic engineering components of medium complexity in a layer-by-layer manner. The process is of significant interest to aerospace and other industry sectors due to its potential to reduce cost and lead-time for high value and critical components when compared to conventional manufacturing methods such as machining from solid billet or forgings.Residual stress and distortion are some of the main challenges of the WAAM process when building complex structures. They can lead to cracking, reduced mechanical properties and either result in build failure or require additional down-stream processing to rectify. Current models of residual stress and distortion for additively manufactured parts are computationally intense and unsuitable for Industry where reducing lead-time is vital. Developing computationally efficient models for the prediction of residual stress and distortion of complex additively manufactured parts would be extremely valuable.