Residual Stress Reduction in High Pressure Interpass Rolled Wire+Arc Additive Manufacturing Ti-6Al-4V Components

Wire+arc additive manufacturing (WAAM) components are characterised by high residual stress due to the many consecutive deposition passes. Residual stress results in distortion once the part is unclamped. High-pressure rolling was investigated as a way to address this issue in Ti–6Al–4V linear parts. Rolling loads of 50 kN and 75 kN were investigated. Residual stress measurements, performed with the contour method, showed rolling was successful in reducing residual stress substantially, especially at the interface between the part and the baseplate. High-pressure interpass rolling is likely to facilitate the implementation of WAAM for the manufacture of structural aerospace components.