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Title | The influence of surface irregularities on the mechanical properties of thin-walled wire and arc additively manufactured parts |
Authors |
Molochkov, D.
Kulykovskyi, R. Brykov, M. Hesse, O. |
ORCID | |
Keywords |
additive manufacturing process innovation geometry defect stress concentrator fatigue strength |
Type | Article |
Date of Issue | 2023 |
URI | https://essuir.sumdu.edu.ua/handle/123456789/93134 |
Publisher | Sumy State University |
License | Creative Commons Attribution - NonCommercial 4.0 International |
Citation | Molochkov D., Kulykovskyi R., Brykov M., Hesse O. (2023). The influence of surface irregularities on the mechanical properties of thin-walled wire and arc additively manufactured parts. Journal of Engineering Sciences (Ukraine), Vol. 10(2), pp. A10–A17, doi: 10.21272/jes.2023.10(2).a2 |
Abstract |
Wire and Arc Additive Manufacturing (WAAM) is a metal additive manufacturing process commonly
used to deposition medium to large, near net-shaped parts. It can efficiently use materials and deposit objects with
fewer assembly parts. The main disadvantage of WAAM is the surface quality. This work investigates the geometry
shift defect that could be formed due to the wear of the welding contact tip. As a result of the wear, the filler wire
deviates from the nominal position, and errors occur in the positioning of individual layers of printed parts. The main
objective of this work is to investigate the influence of surface irregularities on the mechanical properties of asdeposited thin-walled WAAM parts. Finite element modeling of static and cyclic tensile and compressive tests showed
that the surface waviness formed during layer-by-layer deposition increases the stress level under static loading applied
transversely to the deposited layers. Surface waviness also significantly reduces the life of parts under cyclic loading.
Replacement of a worn contact tip causes the layers to shift, and the resulting load eccentricity increases the stress
level. Uneven stress distribution throughout the cross section means reduced material usage efficiency. During
compressive loading, the load eccentricity destabilizes, causing the specimen to deform after exceeding the yield
strength in stress concentration zones. The relationship between unmachined and machined walls with equivalent
stresses was obtained, allowing the influence of surface waviness on the strength and durability of structures to be
considered at the design stage. |
Appears in Collections: |
Journal of Engineering Sciences / Журнал інженерних наук |
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Molochkov_jes_2_2023.pdf | 794,71 kB | Adobe PDF | 4662 |
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