What question did this study set out to answer?

This study aims to predict thermal cycles and residual stresses during wire arc additive manufacturing of dissimilar metals.

Modelling and prediction of thermal cycles and residual stresses of wire arc additive manufactured dissimilar metal component using finite element analysis

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Randomized trial predicts thermal cycles and residual stresses in dissimilar metal WAAM, suggesting improved manufacturing quality.

This study aims to predict thermal cycles and residual stresses during wire arc additive manufacturing of dissimilar metals.
Developed a three-dimensional finite element analysis (FEA) model for WAAM processes.
Applied the model to nickel aluminium bronze on stainless steel 316 L multilayer depositions.
Validated model through experimental trials using robotic gas metal arc welding and temperature measurement techniques.
Forecasted maximum longitudinal tensile stress of 431.5 MPa within the deposit.
Found peak von Mises stress of 404.5 MPa, close to the yield strength of nickel aluminium bronze.
Identified that bidirectional deposition paths significantly influence thermal gradients and deformation.

Yadav et al. (2026) studied this question.

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