Numerical simulation and experimental validation of twin wire ARC additive manufacturing of CoCrNi-medium entropy alloy

Abstract

This research investigates the design and development of CoCrNi medium entropy alloy (MEA) using Twin Wire Arc Additive Manufacturing (TWAAM), integrating both experimental fabrication and numerical simulation. The CoCrNi MEA, known for its outstanding properties at cryogenic and high temperatures, was fabricated using a GMAW-based TWAAM setup with optimized parameters. Two structures were created: a wall (108 mm x 10 mm x 24 mm) and a plate with 30% bead overlap (108 mm x 24 mm x 6 mm). A 3D transient thermos-mechanical model was developed using Abaqus and Goldak's heat source model, providing insights into temperature distribution and residual stress formation. Numerical results indicated that preheating enhanced layer fusion and reduced residual stresses, which were consistent with experimental observations. This integrated approach highlights the potential of TWAAM for producing high-quality CoCrNi MEA components, underscoring the significance of optimized parameters and effective thermal management. The numerical model serves as a predictive tool for temperature and stress distributions, aiding future process optimizations. This study addresses a critical gap in the additive manufacturing of MEAs with TWAAM.