Calibration and validation of the thermal finite element model for ER-120S-G wire arc directed energy deposition using infrared cameras and thermocouples

Author

Joshua Mykl Bassett, Mississippi State UniversityFollow

Advisor

Kim, Han-Gyu

Committee Member

Sescu, Adrian

Committee Member

Mun, Sungkwang

Date of Degree

8-7-2025

Original embargo terms

Immediate Worldwide Access

Document Type

Graduate Thesis - Open Access

Major

Aerospace Engineering

Degree Name

Master of Science (M.S.)

College

James Worth Bagley College of Engineering

Department

Department of Aerospace Engineering

Abstract

Wire Arc Directed Energy Deposition (WA-DED) is a promising additive manufacturing method for producing large metallic components with high deposition rates and low costs. However, its rapid heat input can lead to residual stress, microstructural changes, and dimensional inaccuracies. Accurate thermal modeling is essential to mitigate these effects. This study presents a thermal calibration of a finite element model (FEM) for ER120S-G using thermocouples and infrared (IR) imaging. Thermal data were gathered from three experiments to complete the calibration of the FEM . Calibration focused on tuning the Goldak heat source parameters, power efficiency, and heat transfer coefficients to minimize discrepancies between simulated and experimental results. Results show power efficiency and heat transfer coefficients significantly affect thermal history, while Goldak parameters influence melt pool shape. The final model demonstrated strong agreement with experimental data, validating the FEM’s predictive accuracy and providing a framework for improved thermal control in WA-DED.

Recommended Citation

Bassett, Joshua Mykl, "Calibration and validation of the thermal finite element model for ER-120S-G wire arc directed energy deposition using infrared cameras and thermocouples" (2025). Theses and Dissertations. 6615.
https://scholarsjunction.msstate.edu/td/6615