Residual stress evaluation using the contour method of an additive manufactured high-strength steel solid cuboid

  • Direct Energy Deposition with Arc (DED-Arc) enables the weight-optimized and near-net-shape manufacturing of complex structures. Lightweight construction principles allow a reduction of CO2 emissions by saving time, costs, and resources. Further optimisations can be achieved by using high-strength steel. This allows for a reduction in wall thickness and optimisation of weight. However, manufacturing intricate geometries using high-strength steels poses challenges in managing residual stresses (RS), which are essential for ensuring the structural integrity of welded components. High residual stresses can increase the risk of cold cracking, arising from the complex interactions between material properties, process conditions, and component design. Despite the availability of suitable filler metals, the lack of comprehensive knowledge and guidelines on residual stress formation limits the industrial application. Therefore, in the present study, the contour method (CM) was used toDirect Energy Deposition with Arc (DED-Arc) enables the weight-optimized and near-net-shape manufacturing of complex structures. Lightweight construction principles allow a reduction of CO2 emissions by saving time, costs, and resources. Further optimisations can be achieved by using high-strength steel. This allows for a reduction in wall thickness and optimisation of weight. However, manufacturing intricate geometries using high-strength steels poses challenges in managing residual stresses (RS), which are essential for ensuring the structural integrity of welded components. High residual stresses can increase the risk of cold cracking, arising from the complex interactions between material properties, process conditions, and component design. Despite the availability of suitable filler metals, the lack of comprehensive knowledge and guidelines on residual stress formation limits the industrial application. Therefore, in the present study, the contour method (CM) was used to analyse the full field longitudinal residual stresses in an solid cuboid component (dimensions: 120 × 50 × 35 mm³) manufactured by DED-Arc. The CM enables the analysis of the two-dimensional map of residual stresses normal to a cutting plane using a finite element model. For this purpose, a solid cuboid component was welded fully automatically with a high-strength solid wire specially adapted for DED-Arc (yield strength > 790 MPa) onto conventionally manufactured substrates made of S690QL. The residual stresses from CM in the volume are compared with residual stress analyses using X-Ray diffraction on the surface. Additionally, comparative data from previous studies on hollow cuboid structures was included in order to identify similarities and differences in the resulting stress state, and to complement and validate the CM results. These results demonstrate the significant influence of the geometry on the residual stress profiles within the solid cuboid in relation to the open hollow.zeige mehrzeige weniger

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Autor*innen:Dirk Schröpfer
Koautor*innen:Gundappa Ashwit Shabdali, Karsten Wandtke, Ronny Scharf-Wildenhain, André Hälsig, Thomas Kannengießer, Jonas Hensel
Dokumenttyp:Vortrag
Veröffentlichungsform:Präsentation
Sprache:Englisch
Jahr der Erstveröffentlichung:2025
Organisationseinheit der BAM:9 Komponentensicherheit
9 Komponentensicherheit / 9.2 Versuchsanlagen und Prüftechnik
9 Komponentensicherheit / 9.4 Integrität von Schweißverbindungen
DDC-Klassifikation:Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten
Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Angewandte Physik
Freie Schlagwörter:Contour method; DED-Arc/M; Filler metals; High-strength steel; Neutron diffraction; Residual stress
Themenfelder/Aktivitätsfelder der BAM:Energie
Energie / Windenergie
Infrastruktur
Infrastruktur / Leichtbau
Material
Material / Additive Fertigung
Material / Degradationsmechanismen
Veranstaltung:4th International Conference on Advanced Joining Processes 2026
Veranstaltungsort:Coimbra, Portugal
Beginndatum der Veranstaltung:16.10.2025
Enddatum der Veranstaltung:17.10.2025
Verfügbarkeit des Dokuments:Datei im Netzwerk der BAM verfügbar ("Closed Access")
Datum der Freischaltung:19.12.2025
Referierte Publikation:Nein
Eingeladener Vortrag (wissenschaftliche Konferenzen):Nein
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