Finite Element Simulation of Hybrid Manufacturing of Ti-6Al-4V by Wire Arc Additive Manufacturing and Rolling

In wire arc additive manufacturing (WAAM), residual stress is easily generated during solidification and subsequent cooling, which affects the formation and use of the components. In this paper, finite element simulations were carried out to investigate the influence of roller reductions on the temperature, stress, strain and residual stress distribution in components during the hybrid forming of Ti-6Al-4V alloy by WAAM and interlayer rolling. The results show that interlayer rolling reduces the residual macroscopic stress significantly in the deposited metal, and at the same time reduces the overall stress on the substrate. Increasing reduction can reduce significantly the macroscopic residual stresses and distorsion of the components. The residual stress can be significantly reduced by profiled roller and increasing rolling reduction, which leads to a new route for the optimization of process in wire arc additive manufacturing.