Residual stress and distortion in arc-directed energy deposition: Formation mechanisms, analysis techniques, and mitigation strategies

Abstract

Arc-directed energy deposition (arc-DED) has gained attention as a promising technology for producing large-size metal components with high deposition rates and lower costs. However, the complex thermal processes involved in the deposition often lead to residual stress (RS) and distortion in deposited parts, which negatively impact the quality and performance of the final products. Therefore, controlling RS and distortion is essential for ensuring the high-quality production of arc-DED components. To mitigate RS and distortion in arc-DED, this paper presents a comprehensive review of the efforts made in previous research. The formation mechanisms of RS and distortion in arc-DED are analyzed, the influencing factors are discussed, the analysis techniques for RS and distortion are introduced, and the mitigation strategies applicable to different stages of arc-DED are summarized. The paper concludes by providing a prospective outlook on future research directions for mitigating RS and distortion. This review serves as a valuable reference for manufacturing parts with minimal RS and distortion in industrial arc-DED applications.