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Remelting effect on temperature field, residual stress, and distortion in WAAM components
  • Bachelor and Master Thesis
    • Battery research: Selective laser sintering for use in future batteries
    • Evaluation of the influence of particle contamination depending on the separator and compression using the Hi-Pot Test
    • Contacting of metal-polymer current collectors for use in cylindrical cells: Concept development and validation
    • Optimization of a bending test for the mechanical characterization of battery electrodes
    • Influence of cutting process and free cut edge geometry on the Al-5083 fatigue strength
    • Design and testing of a device and method for the in-situ calibration of force sensors in the die casting process
    • Laser beam assembly of lithium metal anodes
    • Laser pretreatment of die-cast aluminium for in-mold assembly with plastic
    • Prediction of component properties in high-pressure die casting using machine learning
    • Remelting effect on temperature field, residual stress, and distortion in WAAM components
    • Residual stress variations during fabrication
    • Conversion and test of a heating system
    • Investigation of the local suitability for adhesive bonding of aluminium die-cast components
    • Investigation of the local suitability for welding of aluminium die-cast components
    • Influence of thermal cutting processes on the quality of the cut edges
    • Toughness of high strength welded steels

Remelting effect on temperature field, residual stress, and distortion in WAAM components

Background

Wire-arc additive manufacturing (WAAM) process has been widely applied for the production of large-scale defense and aerospace components since it combines traditional arc welding for additive manufacturing (AM) aims and the wire material is available in many different grades with defined quality. Furthermore, the WAAM process provides a higher deposition rate resulting in high productivity. Nevertheless, residual stresses and distortion are unavoidably generated in the WAAM components because of the non-uniform temperature field produced by the localized arc energy input. Residual stresses might affect the structural integrity and service life. Additional costs and schedule delay are incurred for straightening distortion. Therefore, it is necessary to accurately predict temperature field, residual stress and distortion at the design stage.

The heat in the layers can be conducted mainly in the monotonical direction in WAAM structures, which is quite different from that in weldments. A larger portion of the former layer might be remelted by the later layer in WAAM components. However, it is still unknown whether the remelting effect has a great influence on the predicted residual stress and distortion in WAAM components. In other words, should the remelting effect be considered in numerical simulation? If yes, how to consider this? The current work will numerically and experimentally clarify the impact of the remelting effect on the temperature field, residual stress, and distortion in WAAM components.

Task

First of all, WAAM experiments will be performed. During WAAM process, the thermocouples will be arranged to measure thermal cycles. After WAAM process, macro and micrograph will be observed. Furthermore, residual stresses and distortion will be measured. Then, numerical simulation will be carried out to predict the temperature field, residual stress, and distortion. Finally, the influence of the remelting effect on the temperature field, residual stress, and distortion in WAAM components is clarified.

Schematic representation of WAAM component

WAAM component

In the context of a student thesis the following fields of activity arise:

  • Literature research on this topic
  • Performing welding experiments
  • Results analyses, discussion, and written elaboration

Amount of work

The scope of the work is scalable and therefore allows for a bachelor’s thesis, student research project, and master’s thesis. A detailed assignment can be requested from the supervising research assistant. The time for familiarization is given under supervision.

Requirements

  • Known requirements of the faculty for the submission of a student research project or thesis.
  • Commitment and fun in WAAM experiments and numerical simulation.
  • Time for familiarization under supervision.
  • Fluent English and German

Start

The work can start immediately.

Dr. Ing. Jiamin Sun
+ 49 531 391 95513
jiamin.sun(at)tu-braunschweig.de
Dr.-Ing. Jiamin Sun
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