Thermal Modeling of Wire Arc Additive Manufacturing Process Using COMSOL Multiphysics

Wire arc additive manufacturing (WAAM) is one of the emerging AM processes used to fabricate medium to large size components based on the principle of direct energy deposition (DED). Despite having several benefits of the WAAM process, few limitations such as parts distortion and induced residual stress have been a cause of concern in this area. Therefore, the work focuses on finite element process simulation and modeling of thermal cycle prevailed during the fabrication of multi-layered stainless steel (SS316L) wall using WAAM. The model is developed using the COMSOL Multiphysics® software. The simulation results predict the thermal history of the wall fabricated at the selected process parameters. Thus, the model helps in controlling the thermal gradient and the residual stress induced due to non-uniform cooling cycle developed during the manufacturing process. The effective study and altering the process input parameters cutoff a large number of trial experiments and save the production time and associated material loss.