Modelling and prediction of thermal cycles and residual stresses of wire arc additive manufactured dissimilar metal component using finite element analysis

Abstract The accurate prediction of thermal cycles is essential for optimizing wire arc additive manufacturing (WAAM) of dissimilar metal depositions, particularly for high-performance maritime components. This study presents a three-dimensional finite element analysis (FEA)-based model for simulating thermal cycles, deformation and residual stresses in WAAM. This model was applied to multilayer deposition of nickel aluminium bronze (NAB) on Stainless Steel 316 L (SS316L). The methodology was validated through experimental trials using a robotic gas metal arc welding (GMAW) welding setup, integrated with infrared thermography and thermocouple measurements. Results indicate that the bidirectional deposition path and subsequent preheating effects significantly influence the thermal gradients and cumulative distortion. The residual stress analysis forecasts a maximum longitudinal tensile stress of 431.5 MPa within the deposit and a peak von Mises stress reaching 404.5 MPa, which approaches the yield strength of the NAB material. The results of this study provide an important understanding of the thermal behavior of dissimilar metal WAAM processes and offer valuable guidance for the fabrication of high-quality parts in industrial applications.