Effect of deposition path on the thermomechanical coupling and deformation mechanisms of multiribbed aluminum-alloy plate structures

A combined numerical–experimental approach was employed to elucidate the effect of the wire arc-directed energy deposition path on the thermomechanical coupling and macroscopic deformation of multiribbed aluminum-alloy plate structures. A three-dimensional thermomechanical finite element model was developed by incorporating a substructure decoupling methodology with three path-planning solutions: radial outward deposition, contour inward deposition, and lateral progression deposition. Clear correlations were revealed between the path planning strategy and the thermal–mechanical-deformation responses through temperature field reconstruction, residual stress evolution, and deformation analysis. The contour inward deposition path achieved temperature homogenization (radial difference ≤22.3 K) and 39.2% higher cooling efficiency than the radial outward deposition path, but it induced bidirectional stress concentration (80–125 MPa) centrally. The radial outward deposition path offers superior X-direction stress control, whereas the lateral progression deposition path produces a torque effect, thereby increasing the Y-direction stress by 18.9%. The contour inward deposition path limited the Z-direction deformation to 1.102 mm, outperforming the other paths by 11.27% and 13.16% through quasi-symmetric thermal distribution and residual stress self-balancing.