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Residual stress in metal arc additive manufacturing of mill knives cutting edges

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Abstract

The additive manufacture process by electric arc is growing in importance due to its high material deposition rate and application in large components. However, the process also has its limitations regarding the poor quality of the surface finish and the generation of residual stresses that require post-processing for improvements. This work investigates the metal arc additive manufacturing of mill knives cutting edges with the coated electrode DIN 8555 E6-UM-60-S and substrate material, the AISI 1020 steel. In this scenario, the effect on the change of the material deposition direction (longitudinal and transverse direction to sample length) in the residual stresses of the specimens is investigated. The following additional analyses were carried out: temperature behavior on the substrate during deposition and analysis of the microstructure in the material deposition region. The maximum average temperature in the specimens during the longitudinal deposition was 301 °C and, in the transverse, 347 °C. The longitudinal deposition resulted in lower values of residual stresses in relation to transverse deposition (difference of − 62.4 MPa at compression stress and 69.3 MPa at tensile stress).

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Acknowledgments

The authors wish to thank Alisson Nizes in the name of ThyssenKrupp Bilstein Brasil for kindly accepting to make the residual stress measurement. Special thanks to Valter Berloffa, from the department of MTC da Volkswagen do Brasil, Stênio Ferreira Reberte, and Ronald Corsi Rusteiko of Metaurgica Fain.

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  1. Universidade Federal do ABC, Av. dos Estados, 5001, Santo André, SP, 09210-580, Brazil

    A. C. Rusteiko, J. D. Angelo & E. G. D. del Conte

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  1. A. C. Rusteiko
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  2. J. D. Angelo
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  3. E. G. D. del Conte
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Correspondence to E. G. D. del Conte.

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Rusteiko, A.C., Angelo, J.D. & del Conte, E.G.D. Residual stress in metal arc additive manufacturing of mill knives cutting edges. Int J Adv Manuf Technol 104, 4457–4464 (2019). https://doi.org/10.1007/s00170-019-04321-w

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  • DOI: https://doi.org/10.1007/s00170-019-04321-w

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