Comparative Analysis of Residual Stresses in Aluminum Components Produced by Wire Arc Additive Manufacturing (WAAM) and AdditiveFriction Stir Deposition (AFSD)

This collaborative study between ANSTO, University of Palermo, University of Strathclyde, and AFRC investigates residual stresses in aluminum components produced via WAAM and AFSD (including MELD). Using neutron diffraction and ultrasonic techniques, the project aims to characterize and compare stress profiles across processes. The findings will inform process optimization and contribute to a doctoral thesis on in-situ stress measurement in metal additive manufacturing.

This project brings together experts from Australia (ANSTO), Italy (University of Palermo), and the UK (University of Strathclyde and AFRC) to study how different 3D printing methods affect stress inside metal parts. These stresses can make parts weaker or cause them to fail. The team will compare two methods, WAAM and AFSD, to see which one creates less stress in aluminum. They’ll use advanced tools, like neutron beams and sound waves, to look deep inside the metal. The goal is to make 3D-printed parts safer and more reliable, especially for industries like aerospace.