Investigation of Material Model Effect on WAAM SS316L Using Numerical Simulation

This research deals with the influences of material model on deformation which is induced by Wire Arc Additive Manufacturing (WAAM) process simulated by means of thermo-mechanical non-linear FEM method. The feedstock material model is based on stainless steel SS316L which stems from three different sources namely existing database, initial and deposited wire. The actual feedstock materials were analyzed using SEM–EDX and modelled using JMATPRO software. MSC Marc/Mentat is used as the numerical computation software to develop WAAM model and to carryout simulation analysis. The plasticity model of each material is taken based on the isotropic hardening rule with von-mises yield criteria. The strain rate is selected within the range of 0.01–1.0 s⁻¹ and Goldak’s double ellipsoid is chosen as heat source model. Simplified rectangular bead shape as meshed model is developed to avoid the huge pre-processing effort as well as to reduce the computational time. The transient temperature distribution is performed as means of thermal analysis on all three simulation models prior to investigating the deformation result of the WAAM component. Based on the result of the simulation, the noticeable difference can be examined by the transient temperature distribution and substrate distortion. The substrate distortion analysis shows that the distortion pattern based on real SS316L filler wire has more distortion compared to WAAM with default library database of SS316L. By using material model based on database of SS316L, the substrate distortion and transient temperature distribution are lower compared to other models.