Thermal and structural analysis of 304L stainless steel WAAM using finite element analysis

Abstract Finite element analysis (FEA) of the Wire Arc Additive Manufacturing (WAAM) process was conducted to estimate the temperature distribution and distortions during deposition of Stainless Steel AISI 304L using a 0.8 mm wire. Metal Inert Gas (MIG) welding, suitable for WAAM, was used to form wall-type structures through layer-by-layer deposition. The key process parameters included the voltage, current, wire feed rate, torch speed, and number of layers etc. The non-uniform temperature field generated during deposition causes residual stresses and distortions. FEA was employed to predict the temperature distribution during the multi-layer deposition process in wire arc additive manufacturing (WAAM). The simulation involved transient thermal analysis followed by structural analysis to assess distortions. Heat flux was applied per layer, followed by a cooling phase. The effects of non-uniform temperature field generated during deposition were studied experimentally, using a laser pyrometer to measure temperature. The transient temperature profiles obtained from the simulation closely matched the results observed in experimental measurements, demonstrating the accuracy and reliability of the simulation approach. Overall, the study confirmed that controlling process variables in WAAM can improve structural accuracy and help in predicting final component characteristics effectively.