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<p>Wire electron beam directed energy deposition (DED-EB/W) is a highly productive method for the creation of large parts using a wide range of materials. Additively manufactured components may experience thermo-mechanical distortions. During the build-up process, the uneven temperature distribution causes local inelastic deformation, leading to complex residual stress and strain fields within the built and the base plate. Numerical simulations of the build-up process can predict the final component geometry and help develop measures to compensate for shape deviations from distortions. The accuracy of these simulations heavily relies on the quality of thermo-mechanical material data. Due to the lack of reliable data for high-temperature ranges, calibration and validation of numerical simulations based on experiments are often necessary. Without dedicated process monitoring, experiments only reveal post-cooling distortion and miss temporal changes during build-up. In this study, multilayer structures (Inconel 718) are deposited on stainless steel plates (316L) clamped on one side. During the build-up, temperatures are monitored using thermocouples. The chronological progression of distortion is tracked using a displacement sensor. The measurements are used to calibrate and validate the DED-EB/W process simulation. To achieve this, modelling parameters, including the mechanical material model, are adapted accordingly. It is demonstrated that capturing the chronological deformation at a single position is sufficient to characterize the distortion of the entire component and can be effectively used for simulation validation. The validated simulation enables accurate predictions of dynamic and final distortion.</p>

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Experimental and numerical investigation of thermo-mechanical distortion of parts made by wire electron beam directed energy deposition

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年2月16日

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  • Johannes Käsbauer,
  • Bernd Baufeld,
  • Martin Petersen,
  • Andrey Prihodovsky

摘要

Wire electron beam directed energy deposition (DED-EB/W) is a highly productive method for the creation of large parts using a wide range of materials. Additively manufactured components may experience thermo-mechanical distortions. During the build-up process, the uneven temperature distribution causes local inelastic deformation, leading to complex residual stress and strain fields within the built and the base plate. Numerical simulations of the build-up process can predict the final component geometry and help develop measures to compensate for shape deviations from distortions. The accuracy of these simulations heavily relies on the quality of thermo-mechanical material data. Due to the lack of reliable data for high-temperature ranges, calibration and validation of numerical simulations based on experiments are often necessary. Without dedicated process monitoring, experiments only reveal post-cooling distortion and miss temporal changes during build-up. In this study, multilayer structures (Inconel 718) are deposited on stainless steel plates (316L) clamped on one side. During the build-up, temperatures are monitored using thermocouples. The chronological progression of distortion is tracked using a displacement sensor. The measurements are used to calibrate and validate the DED-EB/W process simulation. To achieve this, modelling parameters, including the mechanical material model, are adapted accordingly. It is demonstrated that capturing the chronological deformation at a single position is sufficient to characterize the distortion of the entire component and can be effectively used for simulation validation. The validated simulation enables accurate predictions of dynamic and final distortion.