Evolution of Residual Stresses in Linear Deposition Wire-Based Cladding of Ti-6Al-4V

Abstract

Abstract. Neutron diffraction and curvature measurements were conducted to investigate the residual stresses associated with Plasma Transferred Arc Cladding (PTA) of Ti-6Al-4V on a substrate of the same material. The wire-feed PTA coupled with 3-axis CNC machine was used as an Additive Manufacturing (AM) technique to build parts. A combination of the process parameters was chosen to investigate their effects on residual stress evolution. Neutron Diffraction (ND) measurements of residual strains were performed on the SALSA instrument at the Institut Laue-Langevin (ILL), Grenoble, France. Longitudinal stresses were also inferred by using a Coordinate Measurement Machine (CMM) and Euler-Bernoulli beam theorem. Furthermore, Optical Microscopy (OM) of the cross section of the parts was used to analyse the microstructural evolution. The results show the effect of shorter and longer 'dwell time' between layers on the evolution of residual stresses. IntroductionTitanium alloys have become a material of great interest for different industrial applications due to their excellent corrosion resistance, low density, excellent high temperature mechanical properties and biocompatibility [1,2]. Manufacturing components in a layer-by-layer fashion offers a high geometrical flexibility and great potential for time and cost savings in comparison to conventional manufacturing technologies [3]. The Additive Manufacturing (AM) of small and medium-sized Ti-6Al-4V parts represents an interesting business case for a number of industrial applications.