Comparative residual stress analysis on a DED-Arc manufactured high-strength steel component using the contour method and XRD

  • Lightweight construction is a vital approach for reducing CO₂ emissions. It contributes to the development of more energy-efficient structures and supports the overall goal of achieving carbon neutrality in the transition to sustainable manufacturing. Thus, a topology-optimized design often leads to complex geometries. Additive manufacturing (AM) processes such as direct energy deposition with arc (DED-Arc) offers a great design freedom due to the build-up of components in layers. Furthermore, they enable efficient production due to the high deposition rate, process reliability and good automation capability. Further efficiency can be achieved through weight optimization, enabled by high-strength steels. However, a major challenge is the process induced residual stresses (RS) in the component. High tensile residual stresses are detrimental as they increase the risk of cold cracking. Knowledge of residual stress distribution is crucial for predicting service life of the component andLightweight construction is a vital approach for reducing CO₂ emissions. It contributes to the development of more energy-efficient structures and supports the overall goal of achieving carbon neutrality in the transition to sustainable manufacturing. Thus, a topology-optimized design often leads to complex geometries. Additive manufacturing (AM) processes such as direct energy deposition with arc (DED-Arc) offers a great design freedom due to the build-up of components in layers. Furthermore, they enable efficient production due to the high deposition rate, process reliability and good automation capability. Further efficiency can be achieved through weight optimization, enabled by high-strength steels. However, a major challenge is the process induced residual stresses (RS) in the component. High tensile residual stresses are detrimental as they increase the risk of cold cracking. Knowledge of residual stress distribution is crucial for predicting service life of the component and structural integrity assessment, especially for safety critical applications. Therefore, this study focuses on the use of Contour method (CM) to analyse the full field longitudinal residual stresses in an open hollow cuboid component (dimensions: 120 x 50 x 30 mm3) manufactured by DED-Arc (yield strength > 730 MPa). In the contour method, the component is cut along a desired plane of interest and the contour of deformed cut surface is measured. A finite element model is used to reconstruct the residual stresses field in the 2-dimensional plane of cut. In this paper a modified cutting strategy was employed, post cutting the deformed cut surfaces were measured utilizing two surface measurement techniques i.e., coordinate measuring machine (CMM) and a 3D Scanner. The accuracy of the contour method was validated against surface stresses measured using X-ray diffraction. Additionally, a comparison of neutron diffraction experiments was conducted. The residual stresses were further correlated with hardness measurements. The results from surface measurement techniques showed good agreement regarding the measured displacement contours and the contour method results revealed peak stresses in the DED-Arc walls, bending deformation in substrate induces tensile stresses at the bottom of the substrate plate and compressive stresses in the middle top region. The residual stresses obtained from diffraction and contour method showed a good agreement and correlated qualitatively with the hardness measurements.zeige mehrzeige weniger

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Autor*innen:Dirk Schröpfer
Koautor*innen:Gundappa Ashwit Shabdali, Karsten Wandtke, Arne Kromm, Thomas Kannengießer, Ronny Scharf-Wildenhain, André Hälsig, 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 / Ingenieurbau
Freie Schlagwörter:Contour method; DED-Arc/M; Filler metals; High-strength steel; Neutron diffraction; Residual stress; XRD
Themenfelder/Aktivitätsfelder der BAM:Energie
Energie / Windenergie
Infrastruktur
Infrastruktur / Leichtbau
Material
Material / Additive Fertigung
Material / Degradationsmechanismen
Veranstaltung:78th IIW Annual Assembly and International Conference on Welding and Joining
Veranstaltungsort:Genoa, Italy
Beginndatum der Veranstaltung:22.06.2025
Enddatum der Veranstaltung:27.06.2025
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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