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<p>Wire arc additive manufacturing (WAAM) enables the efficient fabrication of large-scale sandwich structures but often generates high residual stresses. This study investigated the influence of deposition strategy on residual stress in WAAM of sandwich structures. A thermo-mechanical coupling model was proposed to simulate the WAAM. The thermal model was validated by recording the temperature cycling profile with a K-type thermocouple and measuring the melt pool temperature field by thermal imaging. The thermal stress model was validated through the blind hole method and the contour method. The analysis revealed that high radial tensile stresses occurred on the grilles of the sandwich structure, whereas circumferential tensile stresses were primarily distributed along the inner and outer walls. Optimizing the deposition strategy, specifically using path 2 (inner wall - grille - outer wall), reduced radial tensile stresses on the grilles by 203 MPa and circumferential tensile stresses on the inner and outer walls by 222 MPa.</p>

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Effects of deposition strategy on residual stresses in wire arc additive manufacturing of sandwich structures

  • 期刊论文

  • 发表日期：

    2026年1月10日

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  • Xiaolei Zhu,
  • Yaosheng Liang,
  • Feng Yang,
  • Xiaofeng Lu,
  • Jian Wang

摘要

Wire arc additive manufacturing (WAAM) enables the efficient fabrication of large-scale sandwich structures but often generates high residual stresses. This study investigated the influence of deposition strategy on residual stress in WAAM of sandwich structures. A thermo-mechanical coupling model was proposed to simulate the WAAM. The thermal model was validated by recording the temperature cycling profile with a K-type thermocouple and measuring the melt pool temperature field by thermal imaging. The thermal stress model was validated through the blind hole method and the contour method. The analysis revealed that high radial tensile stresses occurred on the grilles of the sandwich structure, whereas circumferential tensile stresses were primarily distributed along the inner and outer walls. Optimizing the deposition strategy, specifically using path 2 (inner wall - grille - outer wall), reduced radial tensile stresses on the grilles by 203 MPa and circumferential tensile stresses on the inner and outer walls by 222 MPa.