ISIS Neutron and Muon Source Data Journal

Residual Stress Analysis on Wall Structure Fabricated by Hybrid WAAM- GMAW? Milling Approach Utilizing Neutron Radiography

Abstract: Wire arc additive manufacturing (WAAM) based on gas metal arc welding (GMAW) offers high deposition capability and is cost-effective. However, several challenges arise during the WAAM-GMAW process, such as heat accumulation and residual stresses, which result in geometric irregularities. The wall structure created using the WAAM-GMAW process is then milled to achieve accurate and precise surface finishes. The milling process has a limited cutting range, depending on the tool length capability. Therefore, simultaneous processing of WAAM-GMAW and milling is necessary for a continuous process. This study aims to investigate the changes in residual stresses in an ER5356 wall structure fabricated with a hybrid WAAM-GMAW-milling process on an AA6061 substrate. Experiments were conducted using the WAAM-GMAW process to create a wall structure with a specific heat input, achieving a specific height, and then milling, simultaneously alternating between WAAM-GMAW and milling. Residual stresses were quantified using neutron diffraction at the ENGIN-X beamline of the ISIS Neutron Source. Neutron diffraction measurement will be carried out using a gauge volume of 2 x 2 x 2 mm.The measurement time is estimated to be 15 minutes per measurement point. Therefore, in total, 15 mins x 20 points x 2 measurement direction. The study contributes to the simultaneous analysis of heat input and process stages in hybrid WAAM GMAW milling on residual stress distribution in wall structures. .

Principal Investigator: Professor Ario Sunar Baskoro
Local Contact: Dr Tung Lik Lee
Experimenter: Mr Agus SIFA

DOI: 10.5286/ISIS.E.RB2610340

ISIS Experiment Number: RB2610340

Publisher: STFC ISIS Neutron and Muon Source

Data format: RAW/Nexus
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Data Citation

The recommended format for citing this dataset in a research publication is as:
[author], [date], [title], [publisher], [doi]

For Example:
Professor Ario Sunar Baskoro et al; (2026): Residual Stress Analysis on Wall Structure Fabricated by Hybrid WAAM- GMAW? Milling Approach Utilizing Neutron Radiography, STFC ISIS Neutron and Muon Source, https://doi.org/10.5286/ISIS.E.RB2610340

Data is released under the CC-BY-4.0 license.