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<p>This study investigates the influence of variable heat accumulation on microstructural evolution, layer defect formation, and thermomechanical behavior in wire arc additive manufacturing (WAAM)-fabricated 308&#xa0;L austenitic stainless steel (ASS). Heat accumulation was controlled through the thin-walled structure shape, interlayer dwell time (IDT), and torch travel speed (TS). An orthogonal L9 design of experiments identified optimal parameter combinations that increased microhardness and minimized its variability, while a decoupled finite element (FE) model correlated thermal field with distortion and residual stresses on WAAM builds deposited on ASTM 36 and ASS 304&#xa0;L substrates. The increase in heat accumulation reduced interlayer thermal gradients and residual stress levels but also decreased delta-ferrite content (&lt; 1.2%), thereby promoting hot cracking. A uniform cooling rate in square and cylindrical structures led to the transformation of columnar dendrites into granular austenite microstructure and reduced tensile residual stresses. The combination of low substrate thickness (6.3&#xa0;mm) and clamping elevated residual stress magnitudes in the first layers, indicating that thin ASS 304&#xa0;L substrates require additional heat-dissipation strategies during WAAM.</p>

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Influence of variable heat accumulation on defects formation, mechanical response and thermomechanical performance of austenitic stainless-steel WAAM structures: statistical-numerical- experimental approach

  • 期刊论文

  • 发表日期：

    2026年5月7日

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  • Victor García-García,
  • Benjamin Max Medina-Prieto,
  • Emmanuel Reyes-Gordillo,
  • Cielo Rodriguez-García,
  • Francisco Reyes-Calderón,
  • Nereyda Alcantar-Mondragón

摘要

This study investigates the influence of variable heat accumulation on microstructural evolution, layer defect formation, and thermomechanical behavior in wire arc additive manufacturing (WAAM)-fabricated 308 L austenitic stainless steel (ASS). Heat accumulation was controlled through the thin-walled structure shape, interlayer dwell time (IDT), and torch travel speed (TS). An orthogonal L9 design of experiments identified optimal parameter combinations that increased microhardness and minimized its variability, while a decoupled finite element (FE) model correlated thermal field with distortion and residual stresses on WAAM builds deposited on ASTM 36 and ASS 304 L substrates. The increase in heat accumulation reduced interlayer thermal gradients and residual stress levels but also decreased delta-ferrite content (< 1.2%), thereby promoting hot cracking. A uniform cooling rate in square and cylindrical structures led to the transformation of columnar dendrites into granular austenite microstructure and reduced tensile residual stresses. The combination of low substrate thickness (6.3 mm) and clamping elevated residual stress magnitudes in the first layers, indicating that thin ASS 304 L substrates require additional heat-dissipation strategies during WAAM.