Finite element analysis of the effect of ultrasonic impact on the stress of aluminum alloy arc additive manufacturing

The finite element analysis was used to numerically simulate the process of arc additive manufacturing of 2219 aluminum alloy under ultrasonic impact, and the changes in stress fields and component deformation were studied. The results show that the additional ultrasonic impact can reduce the stress concentration at the edge of the sediment and at the area close to the sediment in the substrate during the multi-layer multi-channel deposition. Additional ultrasonic impact during multi-layer multi-channel deposition can effectively reduce the stress inside the sediment. After the ultrasonic impact, the stress range at the interface between layers decreased from 156.1 − 211.6 MPa to 138.8 − 181.9 MPa, and the average residual stress on the surface decreased by 22.3%. Under the ultrasonic impact, the maximum deformation of multi-layer multi-pass arc additive component decreased from 0.61 mm to 0.53 mm, and the average deformation decreased from 0.33 mm to 0.27 mm. The stress distribution on the upper surface of the multi-layer sediment calculated by the finite element is similar to that of the measured in actual experiment, which proves that the simulation results are reliable.