Effects of Process Variants on Residual Stresses in Wire Arc Additive Manufacturing of Aluminum Alloy 5183

Karan Derekar, Bilal Ahmad, Xiang Zhang, Sameehan Joshi, Jonathan Lawrence, Lei Xu, Adrian Addison, Geoff Melton

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    14 Citations (Scopus)
    157 Downloads (Pure)


    Development of residual stress of high magnitude, to the extent of material yield strength and in some cases higher than yield strength, is one of the major challenges faced by components produced using the wire arc additive manufacturing (WAAM). This study focuses on aluminum alloy 5183 with respect to the residual stress formation and distribution in WAAM builds. Residual stresses were determined using the contour method. The effects of processing conditions, such as substrate thickness, interlayer temperature, and deposit height on the magnitude and distribution of residual stresses were investigated. Substrate thickness was found to have a major influence on the residual stress distribution along deposit height. Tensile residual stress up to the value of the material yield strength was present. The majority part of the deposit showed tensile stress while substrate showed compensating compressive residual stress. Lower interlayer temperature samples exhibited residual stresses of higher degree of magnitude compared with sample produced using higher interlayer temperature. Deposit height, i.e., total number of layers affected stress distribution pattern similar to substrate thickness.

    Original languageEnglish
    Article number071005
    Number of pages35
    JournalJournal of Manufacturing Science and Engineering
    Issue number7
    Early online date8 Dec 2021
    Publication statusPublished - 1 Jul 2022

    Bibliographical note

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    • aluminum alloy 5183
    • contour method
    • residual stress
    • wire arc additive manufacturing (WAAM)

    ASJC Scopus subject areas

    • Control and Systems Engineering
    • Mechanical Engineering
    • Computer Science Applications
    • Industrial and Manufacturing Engineering


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