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Advanced FE Modeling for Predicting Component Properties in Additive Manufacturing

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Abstract:

Wire arc directed energy deposition (WA-DED) is a cost-efficient additive manufacturing process with high deposition rates, yet the prediction of resulting mechanical properties remains challenging due to repeated thermal cycling and associated microstructural changes. Accordingly, this work aims to validate a hardness prediction model for DIN SG2 by Härtel et al. For this purpose, a demonstrator was designed, manufactured, and simulated using a thermal finite element model in the standard software Simufact Welding 2025. Since the DED module of the software used does not adequately represent active interlayer cooling, four substitute models for the convective heat transfer coefficient were implemented and evaluated. In addition, the original hardness prediction model was refined to consider complex path planning, remelting effects and a material-dependent lower temperature limit for tempering or heat treating the material. Using a substitute model that adjusts the convective heat transfer coefficient over time, the improved hardness prediction the adjusted hardness prediction model achieved an accuracy of ±5% for 81 of 88 evaluated measurement points. In order to enable an efficient and reproducible comparison between simulation and experiment, a Python evaluation script was developed. This tool automatically identifies relevant temperature peaks, correlates them with hardness data, creates individual evaluation diagrams and a comparison diagram, and exports all processed data to an Excel file.

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Info:

Periodical:

Key Engineering Materials (Volume 1047)

Pages:

299-311

Online since:

April 2026

Authors:

Lennart Grüger*, Tim Sebastian Tübbicke, Huan Po Huang, Sebastian Härtel

Keywords:

Additive Manufacturing, FEM-Simulation, Material Modeling

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RIS, BibTeX

Permissions:

Creative Commons CC BY 4.0

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* - Corresponding Author

References

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