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<p>Understanding the relationship between wall geometry and material properties in wire-arc directed energy deposition (DED-Arc) is critical for process qualification and part design optimization. This work combines finite element thermal modeling and tensile testing to investigate how meander width, relative to characteristic melt pool dimensions, influences thermal history and yield strength in Inconel 625 walls. Three wall regimes are identified based on the interaction between meander width and melt pool geometry: single-track-like, thin wall, and thick wall, governed by the meander width normalized by the melt pool width and length rather than absolute wall thickness. Each regime exhibits distinct remelting behavior, ranging from predominantly continuous cooling in the single-track-like regime to multiple within-layer remelting events as the meander width approaches and exceeds the melt pool length. Thick-wall conditions achieve up to 40&#xa0;MPa (~&#xa0;10%) higher yield strength than single-track-like walls. This strengthening is hypothesized to arise from increased intralayer remelting and diversified thermal gradients, which may promote grain refinement, texture weakening, and elevated dislocation density. The proposed geometry-based scaling framework provides a physically motivated approach for predicting thermal–mechanical trends and identifying regime transitions in DED-Arc builds.</p>

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Three-Wall Thickness Regimes Governing Yield Strengths in Wire-Arc Directed Energy-Deposited Inconel 625

  • 期刊论文

  • 发表日期：

    2026年6月23日

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  • Xavier Jimenez,
  • Jie Song,
  • M. Ali Yikilmaz,
  • Yao Fu,
  • Sean Thompson,
  • Albert C. To

摘要

Understanding the relationship between wall geometry and material properties in wire-arc directed energy deposition (DED-Arc) is critical for process qualification and part design optimization. This work combines finite element thermal modeling and tensile testing to investigate how meander width, relative to characteristic melt pool dimensions, influences thermal history and yield strength in Inconel 625 walls. Three wall regimes are identified based on the interaction between meander width and melt pool geometry: single-track-like, thin wall, and thick wall, governed by the meander width normalized by the melt pool width and length rather than absolute wall thickness. Each regime exhibits distinct remelting behavior, ranging from predominantly continuous cooling in the single-track-like regime to multiple within-layer remelting events as the meander width approaches and exceeds the melt pool length. Thick-wall conditions achieve up to 40 MPa (~ 10%) higher yield strength than single-track-like walls. This strengthening is hypothesized to arise from increased intralayer remelting and diversified thermal gradients, which may promote grain refinement, texture weakening, and elevated dislocation density. The proposed geometry-based scaling framework provides a physically motivated approach for predicting thermal–mechanical trends and identifying regime transitions in DED-Arc builds.