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<p>This study develops and validates a hybrid numerical-empirical framework to predict surface residual stresses in SS316L components fabricated via Wire Arc Additive Manufacturing (WAAM), with a specific focus on remanufacturing applications. A transient thermo-mechanical finite element model was constructed using ANSYS Workbench 2022 R2 to simulate heat transfer and stress evolution during deposition. The role of the substrate in influencing thermal dissipation and stress development was explicitly addressed, given its importance in reused or recycled base materials. Experimental validation was conducted through high-frequency temperature acquisition at multiple substrate locations and residual stress measurements using the micro-indentation technique and the hole-drilling strain-gauge method in accordance with ASTM E837-20. An empirical model was formulated for rapid residual stress estimation, exhibiting deviations of only 1.82%, 6.45%, 6.24%, and 3.52% compared to finite element predictions at four key locations. Additionally, quantitative phase analysis based on ASTM E1245-03 (2019) using ImageJ software revealed phase fractions of 82.8% γ-austenite and 17.2% δ-ferrite. The novelty of this work lies in its integrative methodology that combines high-fidelity simulation, rapid empirical modelling, and robust experimental validation, while accounting for substrate effects—an often overlooked factor in WAAM-based remanufacturing. The findings offer a reliable and computationally efficient approach for residual stress assessment, with strong implications for optimizing WAAM processes in industrial remanufacturing workflows.</p>

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Effects of substrate in residual stress evolution: a hybrid numerical-empirical prediction for WAAM-remanufactured SS316L components

  • 期刊论文

  • 发表日期：

    2025年7月6日

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  • Chethan Kumar N,
  • Suyog Jhavar,
  • Monsuru Ramoni

摘要

This study develops and validates a hybrid numerical-empirical framework to predict surface residual stresses in SS316L components fabricated via Wire Arc Additive Manufacturing (WAAM), with a specific focus on remanufacturing applications. A transient thermo-mechanical finite element model was constructed using ANSYS Workbench 2022 R2 to simulate heat transfer and stress evolution during deposition. The role of the substrate in influencing thermal dissipation and stress development was explicitly addressed, given its importance in reused or recycled base materials. Experimental validation was conducted through high-frequency temperature acquisition at multiple substrate locations and residual stress measurements using the micro-indentation technique and the hole-drilling strain-gauge method in accordance with ASTM E837-20. An empirical model was formulated for rapid residual stress estimation, exhibiting deviations of only 1.82%, 6.45%, 6.24%, and 3.52% compared to finite element predictions at four key locations. Additionally, quantitative phase analysis based on ASTM E1245-03 (2019) using ImageJ software revealed phase fractions of 82.8% γ-austenite and 17.2% δ-ferrite. The novelty of this work lies in its integrative methodology that combines high-fidelity simulation, rapid empirical modelling, and robust experimental validation, while accounting for substrate effects—an often overlooked factor in WAAM-based remanufacturing. The findings offer a reliable and computationally efficient approach for residual stress assessment, with strong implications for optimizing WAAM processes in industrial remanufacturing workflows.