Finite element simulation of hybrid manufacturing of Ti–6Al–4 V by arc-directed energy deposition and friction stir processing

FSP is a novel technology that can improve the microstructure and mechanical properties of ADED. In this study, an FSP-ADED hybrid manufacturing finite element model was constructed for stress and strain simulating the Ti–6Al–4 V alloy. The results show that continuous shrinkage of the deposition wall was broken after inter-layer FSP. The minimum tensile RS was obtained near the wall top. The tensile RS was increased after the deposition of the second layer; however, the overall stress level was lower than that of ADED alone. After two layers of FSP, the average value of longitudinal stress in the stirred zone was reduced by 54%. The warping deformation of hybrid manufactured components was reduced by 30.9%. It was proved that FSP-ADED hybrid manufacturing is an effective method to reduce RS and deformation of titanium alloy large-scale structural parts in the aerospace field.