Dissemination DeliverablesD3.2

Deliverable 3.2

Abstract

Deliverable 3.2 reports the activities regarding the development of thermal model within the CIRCULAR WELD project. The document presents a finite element method (FEM)-based approach for modeling and simulating the thermal behavior of the Wire Arc Additive Manufacturing (WAAM) Dot-by-Dot (DbD) process. DbD WAAM poses unique challenges, including rapid thermal cycling, complex interpass temperature control, and difficulty in predicting part geometry. A thermal simulation workflow was developed and implemented using Simufact Welding, incorporating a modified Goldak heat source, temperature-dependent heat transfer coefficients, and a calibration methodology based on experimental thermal data. The model was validated across multiple test cases with varying dot sizes and idle times, achieving a steady-state interpass temperature prediction error below 10% in most scenarios. Furthermore, the model was applied to a more complex “X” joint geometry, demonstrating its effectiveness in capturing the transient thermal behavior of intersecting paths. The proposed FEM framework enables accurate prediction of thermal history and interpass temperature, facilitating improved process control, reduced experimental trials, and enhanced manufacturability of complex components.

Table of contents

1.    INTRODUCTION

2.    IMPLEMENTATION

3.    APPLICATIONS