Measurement and modelling of residual stress in wire-feed additively manufactured titanium

Residual stresses were characterised in a wire-feed additively manufactured titanium alloy component. A numerical simulation based on the inherent strain method was used to model residual stresses arising from the manufacturing process. The contour method was used to experimentally determine the residual stress field. High tensile residual stresses were seen at and around the interface of the substrate and the deposited metal. Compressive residual stresses were present in the substrate and at the top of the deposit. The satisfactory correlation was achieved between the results from the numerical simulation and the contour method, except for the location of the root of the deposit. The effect of pre-heating the sample substrate on the residual stress distribution is also discussed.