Residual Stress Evolution during Slot Milling for Repair Welding and Wire Arc Additive Manufacturing of High-Strength Steel Components

High-strength steels offer potential for weight optimization due to reduced wall thicknesses in modern constructions. Additive manufacturing processes such as Wire Arc Additive Manufacturing (WAAM) enable the resource-efficient production of structures. In the case of defects occurring in weld seams...

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Bibliographic Details
Published inMetals (Basel ) Vol. 14; no. 1; p. 82
Main Authors Wandtke, Karsten, Becker, Amadeus, Schroepfer, Dirk, Kromm, Arne, Kannengiesser, Thomas, Scharf-Wildenhain, Ronny, Haelsig, André, Hensel, Jonas
Format Journal Article
LanguageEnglish
Published Basel MDPI AG 01.01.2024
Subjects
3D printing
Additive manufacturing
Arc welding
Axial stress
Cooling
digital image correlation
Digital imaging
Ductility
High strength steel
High strength steels
Machining
Maintenance and repair
Manufacturers
Manufacturing
Mechanical properties
Production processes
Repair welding
Residual stress
Seam welds
Slot milling
Steel
Steel, High strength
WAAM
Welding
Wire
Wire industry
Yield stress
Germany
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Summary:High-strength steels offer potential for weight optimization due to reduced wall thicknesses in modern constructions. Additive manufacturing processes such as Wire Arc Additive Manufacturing (WAAM) enable the resource-efficient production of structures. In the case of defects occurring in weld seams or WAAM components due to unstable process conditions, the economical solution is local gouging or machining and repair welding. It is important to understand the effects of machining steps on the multiaxial stress state in conjunction with the design-related shrinkage restraints. Research into how welding and slot milling of welds and WAAM structures affects residual stresses is still lacking. For this reason, component-related investigations with high-strength steels with yield strengths ≥790 MPa are carried out in our research. In-situ digital image correlation (DIC) and ex-situ X-ray diffraction (XRD) were used to analyze the stresses and strains induced on specimens during and after milling. The systematic analyses revealed a significant interaction of the stiffness and microstructure of the specimens with the initial residual stresses induced by welding. Subsequent repair welds can result in significantly higher residual stresses.
ISSN:2075-4701
2075-4701
DOI:10.3390/met14010082