Influence of deposition path strategy on residual stress and deformation in weaving wire-arc additive manufacturing of disc parts

Deposition pattern and path-planning deposition strategy have significant impacts on the deformation and residual stress of components during a wire-arc additive manufacturing (WAAM) process. This work comparatively addressed the influence of weaving and non-weaving deposition patterns on the distributions of residual stress and warping deformation during a single-bead-on-plate WAAM process. Further, four path strategies with different deposition sequences (in-out and out-in) and deposition directions (alternate and consistent) were designed for a weaving WAAM process of disc part, and their impacts on temperature history, warping deformation, and residual stress were comparatively analyzed through thermal-mechanical coupling finite element (FE) method. Simulation and experiment results manifest that, compared to the non-weaving pattern, the weaving deposition pattern results in more uniform deformation and lower residual stress on the deposited plate due to wider and shallower molten pool. Comparison results for the four deposition path strategies in the weaving WAAM process of disc part suggest that the out-in deposition sequence exhibits faster heat dissipation and uniform temperature field during the cooling stage, resulting in reduced warping deformation and residual stress on the workpiece. Moreover, uniform deformation is observed across path strategies employing alternate deposition direction. The out-in alternate deposition path strategy was identified as the optimal choice for the weaving WAAM process of disc part. Finally, physical experiments validated the simulated warping deformation of disc parts under different deposition path strategies. This work contributes to the design and optimization of weaving WAAM process for disc-shaped components.