High fidelity thermo-mechanical model of in-situ micro-rolling in laser-directed energy deposition: multi-track multi-layer case

High fidelity thermo-mechanical model of in-situ micro-rolling in laser-directed energy deposition: multi-track multi-layer case | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article High fidelity thermo-mechanical model of in-situ micro-rolling in laser-directed energy deposition: multi-track multi-layer case Ravi Raj, Louis Ngai Sum Chiu, Deepak Marla, Aijun Huang This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6216721/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract In-situ rolling during Directed Energy Deposition (DED) at elevated temperatures has been shown to enhance build quality. However, experimentally characterizing the deformation mechanisms that drive these improvements remains challenging. While previous thermo-mechanical finite element analyses (FEA) have focused on single-track and thin-wall multi-layer cases, the more realistic multi-track, multi-layer scenarios remain largely unexplored. This study develops and validates an FEA framework for in-situ rolled DED in a three-track, three-layer Ti-6Al-4V deposition, achieving thermal predictions with95% accuracy against experiments. Unlike single-track multi-layer cases reported in the literature, where in-situ rolling significantly influences thermal behaviour, its impact in the multi-track scenario is minor due to increased lateral heat diffusion. In-situ rolling effectively induces compressive plastic strain across all three layers, significantly mitigating tensile residual stresses that typically develop in unrolled cases. Furthermore, the study reveals that deposition and in-situ rolling at the top have a more pronounced influence on thermal and deformation cycles than at the side. These findings provide valuable insights for optimizing multi-track, multi-layer DED, enabling improved metallurgical and mechanical properties in additively manufactured components. Finite element methods Hybrid metal additive manufacturing Ti-6Al-4V In-situ forging Residual stress Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6216721","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":436006007,"identity":"70e1af7d-8dac-4a66-bf89-ae34e4cf32c3","order_by":0,"name":"Ravi Raj","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAAvklEQVRIiWNgGAWjYFCCAyBCQg7MfECKFmMwM4EUuxIbQCRRWswbjz9grmyzSJ8fdvgh0BY7Od0GAlpkDpwxYDzbJpG78XaaAVBLsrHZAQJaJBjOMDA2nAFqmZ0A0nIgcRthLccfgLSkG85O/0CslgMGjA0VEgny0jlE23LG4CBQi+EG6ZyCAwkGxPhF4vjDhw0GdfLys9M3f/hQYSdHUAuDxAFIZBpASELKQYC/AULLNxCjehSMglEwCkYkAAADRET7gTEe7wAAAABJRU5ErkJggg==","orcid":"","institution":"Indian Institute of Technology Bombay","correspondingAuthor":true,"prefix":"","firstName":"Ravi","middleName":"","lastName":"Raj","suffix":""},{"id":436006009,"identity":"96553262-2dd6-41df-acac-0dfc4cf69ac7","order_by":1,"name":"Louis Ngai Sum Chiu","email":"","orcid":"","institution":"Monash University","correspondingAuthor":false,"prefix":"","firstName":"Louis","middleName":"Ngai Sum","lastName":"Chiu","suffix":""},{"id":436006011,"identity":"70735d26-5b3b-4846-ace0-dddd95527b7e","order_by":2,"name":"Deepak Marla","email":"","orcid":"","institution":"Indian Institute of Technology Bombay","correspondingAuthor":false,"prefix":"","firstName":"Deepak","middleName":"","lastName":"Marla","suffix":""},{"id":436006014,"identity":"33d0918f-d64c-406b-8cc5-57acc60e1aee","order_by":3,"name":"Aijun Huang","email":"","orcid":"","institution":"Monash University","correspondingAuthor":false,"prefix":"","firstName":"Aijun","middleName":"","lastName":"Huang","suffix":""}],"badges":[],"createdAt":"2025-03-13 05:53:18","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-6216721/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-6216721/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":89191188,"identity":"09a1b094-08a7-4e23-a212-f763c516f3d8","added_by":"auto","created_at":"2025-08-16 09:01:46","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":859463,"visible":true,"origin":"","legend":"","description":"","filename":"Threetrackthreelayercaseofinsiturollinghybridisation.pdf","url":"https://assets-eu.researchsquare.com/files/rs-6216721/v1_covered_b94aa77b-379d-41bf-b404-63a8e37cef5e.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"High fidelity thermo-mechanical model of in-situ micro-rolling in laser-directed energy deposition: multi-track multi-layer case","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Finite element methods, Hybrid metal additive manufacturing, Ti-6Al-4V, In-situ forging, Residual stress","lastPublishedDoi":"10.21203/rs.3.rs-6216721/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-6216721/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eIn-situ rolling during Directed Energy Deposition (DED) at elevated temperatures has been shown to enhance build quality. However, experimentally characterizing the deformation mechanisms that drive these improvements remains challenging. While previous thermo-mechanical finite element analyses (FEA) have focused on single-track and thin-wall multi-layer cases, the more realistic multi-track, multi-layer scenarios remain largely unexplored. This study develops and validates an FEA framework for in-situ rolled DED in a three-track, three-layer Ti-6Al-4V deposition, achieving thermal predictions with95% accuracy against experiments. Unlike single-track multi-layer cases reported in the literature, where in-situ rolling significantly influences thermal behaviour, its impact in the multi-track scenario is minor due to increased lateral heat diffusion. In-situ rolling effectively induces compressive plastic strain across all three layers, significantly mitigating tensile residual stresses that typically develop in unrolled cases. Furthermore, the study reveals that deposition and in-situ rolling at the top have a more pronounced influence on thermal and deformation cycles than at the side. These findings provide valuable insights for optimizing multi-track, multi-layer DED, enabling improved metallurgical and mechanical properties in additively manufactured components.\u003c/p\u003e","manuscriptTitle":"High fidelity thermo-mechanical model of in-situ micro-rolling in laser-directed energy deposition: multi-track multi-layer case","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-03-31 17:29:23","doi":"10.21203/rs.3.rs-6216721/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"bbb4dfc6-1460-4677-aecc-acdb60474074","owner":[],"postedDate":"March 31st, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2026-01-30T17:28:31+00:00","versionOfRecord":[],"versionCreatedAt":"2025-03-31 17:29:23","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-6216721","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-6216721","identity":"rs-6216721","version":["v1"]},"buildId":"XKTyCvWXoU3ODBz1xrDgd","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}