Residual Stresses in a Wire and Arc-Directed Energy-Deposited Al–6Cu–Mn (ER2319) Alloy Determined by Energy-Dispersive High-Energy X-ray Diffraction

In order to enable and promote the adoption of novel material processing technologies, a comprehensive understanding of the residual stresses present in structural components is required. The intrinsically high energy input and complex thermal cycle during arc-based additive manufacturing typically translate into non-negligible residual stresses. This study focuses on the quantitative evaluation of residual stresses in an Al–6Cu–Mn alloy fabricated by wire and arc-directed energy deposition. Thin, single-track aluminum specimens that differ in their respective height are investigated by means of energy-dispersive high-energy X-ray diffraction. The aim is to assess the build-up of stresses upon consecutive layer deposition. Stresses are evaluated along the specimen build direction as well as with respect to the lateral position within the component. The residual stress evolution suggests that the most critical region of the specimen is close to the substrate, where high tensile stresses close to the material’s yield strength prevail. The presence of these stresses is due to the most pronounced thermal gradients and mechanical constraints in this region.