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Residual stress and deformation in wire-feed electron beam additive manufactured aluminum components

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Abstract

Electron beam additive manufacturing (EBAM) has broad application prospects in the preparation of large structural components such as those in aerospace structures. It is of great significance to have a deep understanding of the residual stress distribution and deformation of EBAM. A three-dimensional transient thermal–mechanical coupling model was established for the comprehensive investigation of the deformation and residual stress of aluminum alloy components prepared by wire-feed EBAM for the first time. The reliability of the simulation model was verified by comparing the predicted temperature, stress and deformation with experimentally measured values. The influence of heat input on residual stress distribution and deformation was studied using the verified model. The simulation results indicate that reducing heat input is an efficient approach to reducing deformation and residual stress. The developed model can be a powerful tool to optimize process parameters to reduce the residual stress and deformation of EBAM aluminum alloy components.

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Acknowledgements

The authors would like to thank the editorial department and the reviewers.

Funding

This work was supported by the Joint Funds of China Academy of Launch Vehicle Technology and University (CALT 2021–24) and the Fund of the State Key Laboratory of Tribology in Advanced Equipment (SKLT2022C20).

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Authors and Affiliations

  1. State Key Laboratory of Tribology in Advanced Equipment, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

    Dongqi Zhang, Dong Du, Shuai Xue, Junjie Qi, Ze Pu & Baohua Chang

  2. Capital Aerospace Machinery Co., Ltd., Beijing, 100076, China

    Yunpeng Lu & Yingying Tang

Authors
  1. Dongqi Zhang
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  2. Dong Du
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  7. Yingying Tang
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  8. Baohua Chang
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Contributions

Conceptualization: Baohua Chang, Dongqi Zhang; methodology: Dong Du, Ze Pu; software: Dongqi Zhang, Yingying Tang; validation: Shuai Xue, Junjie Qi; formal analysis: Dongqi Zhang; investigation: Dongqi Zhang; resources: Yunpeng Lu, Baohua Chang; data curation: Dongqi Zhang; writing-original draft preparation: Dongqi Zhang; writing-review and editing: Baohua Chang; visualization: Baohua Chang; supervision: Dong Du; project administration: Dong Du, Yunpeng Lu; funding acquisition: Baohua Chang.

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Correspondence to Baohua Chang.

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Zhang, D., Du, D., Xue, S. et al. Residual stress and deformation in wire-feed electron beam additive manufactured aluminum components. Int J Adv Manuf Technol 131, 1665–1676 (2024). https://doi.org/10.1007/s00170-024-13169-8

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