Novel process parameters based approach for reducing residual stresses in WAAM

Residual stresses are unfavourable phenomena in wire arc additive manufacturing, which needs to be critically analysed and mitigated. Process parameters play a crucial role in mitigating stress, the work here attempts to analyse strategies to find the best trend of varying the process parameters rather than selecting the optimal process parameters in order to have the least residual stresses. The initial part of work deals with optimising the input parameters assuming uniform value of parameters to build the entire structure wherein local optimal values of current, voltage and welding speed are obtained. However, critically analysing for global optimas, the parameters needed further reduction, which would create nodus of arc stabilities. To address this an innovative procedure is applied wherein a variation trend of parameters along the length of the build structure are used and trend analysis of the output is carried out to find the best and worst case. The study's outputs indicate that the difference in the effective stress formed via designed ideology and the one with uniform parameters on an average scale is 210 MPa. Copyright (C) 2022 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the Third International Conference on Recent Advances in Materials and Manufacturing 2021.