An integrated experimental and computational framework for design and analysis of WAAM fabricated structural elements

Abstract

The current research work presents an integrated experimental and computational framework for characterizing and predicting the mechanical behavior of Wire Arc Additive Manufacturing (WAAM)-produced materials. Tensile samples extracted from a WAAM-fabricated cylindrical tube were tested to evaluate stress-strain and failure behavior. The mechanical properties of WAAM components were compared with those of conventionally manufactured counterparts and benchmarked against industry standards such as EN 1993–1–1. A computational framework based on the Gurson-Tvergaard-Needleman (GTN) model was developed to predict load-displacement curves, local strain, and failure profiles. The framework was thoroughly validated against experimental results both qualitatively and quantitatively. To extend the proposed computational framework to complex geometries, notched specimens with varying radii were tested under uniaxial loads to induce a multiaxial stress state at notch locations. Experimental strain profiles and fractographic analyses were used to validate the numerical predictions, evaluating the proposed framework's robustness and reliability for structural applications. This work establishes a systematic approach to understand WAAM-produced materials and their potential for structural applications under diverse loading conditions.