Control of solid-state phase transformations during the wire arc additive manufacturing process to reduce residual stress and deformation in deposits

Arnoulin, Pauline; Bertrand, Emmanuel; Couturier, Laurent; Gloaguen, David; Girault, Baptiste; Lee, Tung Lik; Kelleher, Joe; Morville, Simon; Courant, Bruno

doi:10.5281/zenodo.17258538

Abstract

The heating and cooling conditions during the wire arc additive manufacturing process (WAAM) generate complex thermal, metallurgical and mechanical phenomena that induce stresses and strains within the part. They are mainly due to incompatibilities between local deformations induced by thermal expansion gradients. In steels, certain phase transformations, between ferrite, austenite and martensite, can also interfere with the state of stress and strain. To reduce residual stresses and strains, we propose to control solid-state phase transformations, through local chemical composition, to drive metallurgical deformations that counter thermal distorsions. To that end, we study the various phase transformations arising from the martensitic, austenitic and ferritic stainless steels combinations. The microstructure of the 12 alloys produced in situ are analysed and related to the deformation and residual stress state, measured by neutron diffraction, to reveal their correlations. Phase evolution has been shown to have a significant influence on the stress establishment in the part, with up to 66% less strain depending on the transformations encountered. These results enable us to identify the chemical compositions for which we obtain the least deformation and stress, and therefore the microstructures to be favoured. Finally, this study paves the way for the development of functionally graded materials produced by WAAM for improved final properties.

Control of solid-state phase transformations during the wire arc additive manufacturing process to reduce residual stress and deformation in deposits

Author: Arnoulin, Pauline; Bertrand, Emmanuel; Couturier, Laurent; Gloaguen, David; Girault, Baptiste; Lee, Tung Lik; Kelleher, Joe; Morville, Simon; Courant, Bruno

Publisher: Zenodo

DOI: 10.5281/zenodo.17258538

Source: https://zenodo.org/records/17258538/files/ARNOULIN_Pauline_AAMS2025_abstract.pdf

AAMS 2025
Con ol o solid-s a e phase ans o ma ions du ing
he wi e a c addi i e manu ac u ing p ocess o educe
esidual s ess and de o ma ion in deposi s
Pauline A noulin1,2,3, Emmanuel Be and3, Lau en Cou u ie 3, Da id Gloaguen2, Bap is e
Gi aul 2, Tung Lik Lee4, Joe Kellehe 4, Simon Mo ille1, B uno Cou an 2
1IRT Jules Ve ne - Nan es Uni e si é, Ins i u de Reche che Technologique Jules Ve ne, p og amme PERFORM, F-
44340 Bouguenais, F ance
2GeM - Nan es Uni e si é, Ecole Cen ale Nan es, CNRS, Ins i u de Reche che en Génie Ci il e Mécanique, GeM,
F-44600 Sain -Nazai e, F ance
3IMN - Nan es Uni e si é, CNRS, Ins i u des Ma é iaux de Nan es Jean Rouxel, IMN, F 44000 Nan es, F ance
4ISIS Neu on and Muon Sou ce, Ru he o d Apple on Labo a o y, Didco , OX11 0QX, Uni ed Kingdom
Keywo ds: WAAM, Solid-S a e Phase T ans o ma ion, S ain, S ess, Mic os uc u e.
Abs ac
The hea ing and cooling condi ions du ing he wi e a c addi i e manu ac u ing p ocess
(WAAM) gene a e complex he mal, me allu gical and mechanical phenomena ha induce
s esses and s ains wi hin he pa . They a e mainly due o incompa ibili ies be ween local
de o ma ions induced by he mal expansion g adien s. In s eels, ce ain phase
ans o ma ions, be ween e i e, aus eni e and ma ensi e, can also in e e e wi h he s a e
o s ess and s ain. To educe esidual s esses and s ains, we p opose o con ol solid-
s a e phase ans o ma ions, h ough local chemical composi ion, o d i e me allu gical
de o ma ions ha coun e he mal dis o sions.
To ha end, we s udy he a ious phase ans o ma ions a ising om he ma ensi ic,
aus eni ic and e i ic s ainless s eels combina ions. The mic os uc u e o he 12 alloys
p oduced in si u a e analysed and ela ed o he de o ma ion and esidual s ess s a e,
measu ed by neu on di ac ion, o e eal hei co ela ions. Phase e olu ion has been
shown o ha e a signi ican in luence on he s ess es ablishmen in he pa , wi h up o 66%
less s ain depending on he ans o ma ions encoun e ed.
These esul s enable us o iden i y he chemical composi ions o which we ob ain he leas
de o ma ion and s ess, and he e o e he mic os uc u es o be a ou ed. Finally, his s udy
pa es he way o he de elopmen o unc ionally g aded ma e ials p oduced by WAAM o
imp o ed inal p ope ies.