Assessment of Destructive and Non-Destructive Residual Stress Measurements for WAAM Components

Monday, October 20, 2025: 9:40 AM
Mr. Markus Domogala , The University of Sydney, Darlington, NSW, Australia
Prof. Kim Rasmussen , The University of Sydney, Darlington, NSW, Australia
Dr. Joseph Polden , University of Wollongong, Wollongong, NSW, Australia
Fernando Valiente Dies , The University of Sydney, Sydney, NSW, Australia
Dr. Tao Wei , ANSTO, Sydney, NSW, Australia
Dr. Ondrej Muránsky , ANSTO, Sydney, NSW, Australia
Prof. Anna Paradowska , The University of Sydney, Sydney, NSW, Australia, ANSTO, Sydney, NSW, Australia
Wire-Arc Additive Manufacturing (WAAM) enables the cost-effective production of large-scale steel structures but introduces significant residual stresses that can compromise structural integrity. This study investigates the residual stress distribution in WAAM-produced 316L stainless steel component using neutron diffraction and the contour method, with particular focus on cross-correlating these two techniques.

Residual stress measurements from both methods show strong agreement, providing valuable input for finite element models (FEM) of the process. Neutron diffraction enables non-destructive subsurface and bulk measurements, but its accuracy heavily depends on the preparation of stress-free reference samples. A detailed analysis of these reference samples revealed a strong crystallographic texture, though the overall variation remained small across the height of the WAAM component.

The contour method, in contrast, is unaffected by texture or chemical composition variations, offering a key advantage over diffraction-based techniques. However, as a destructive method, it is limited to measuring residual stress in a single direction. This study discusses the strengths and limitations of both techniques in the context of WAAM, particularly regarding spatial resolution, reference sample requirements, and applicability to large-scale components.

By refining residual stress measurement methodologies and identifying key constraints, this study advances the approach to residual stress assessment in WAAM printed structures. These findings contribute to improved process control and enhance structural reliability in additive manufacturing for civil and structural applications.

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