Theses and Dissertations
ORCID
https://orcid.org/0009-0005-4375-6419
Advisor
Priddy, Matthew
Committee Member
Bakhtiarydavijani, Amirhamed
Committee Member
Moore, Jacob
Committee Member
Stone, Tonya
Date of Degree
5-15-2026
Original embargo terms
Embargo 2 years
Document Type
Dissertation - Open Access
Major
Engineering (Mechanical Engineering)
Degree Name
Doctor of Philosophy (Ph.D.)
College
James Worth Bagley College of Engineering
Department
Michael W. Hall School of Mechanical Engineering
Abstract
Finite element modeling of directed energy deposition (DED) processes provides a critical foundation for understanding and optimizing thermal-mechanical behavior, residual stress formation, and distortion in large-scale metal additive manufacturing. This dissertation advances predictive modeling of wire-arc directed energy deposition (arc-DED) by investigating the process–property relationship associated with interpass temperature control (ITC) and other thermal management strategies. A calibrated, sequentially coupled thermomechanical framework was developed and validated against experimental thermocouple and neutron diffraction data for Maraging 250 steel thin-wall builds. Three constitutive models—Elastic Perfectly Plastic (EPP), Johnson–Cook (JC), and the Evolving Microstructural Model of Inelasticity (EMMI)—were implemented to assess model fidelity, strain-rate sensitivity, and computational efficiency. The EPP and JC models provided the most accurate and efficient residual-stress predictions, while the EMMI model offered additional microstructural insight at higher computational cost. The framework was then applied to evaluate fixed dwell time (FTC) and interpass temperature- controlled dwell techniques, demonstrating that precise thermal management can reduce residual tensile stress and geometric distortion compared to conventional dwell methods. The modeling methodology was extended to the NIST AM-Bench 2025-04 benchmark geometry, manufactured using laser hot-wire DED with Inconel 718, to explore qualification metrics, sensor-placement strategies, and interpass control scalability for large complex components. Lastly, active cooling approaches were simulated for titanium builds, showing that integrated water-cooled substrates can lower average part temperature by up to 50% and reduce distortion while maintaining stress balance. Collectively, this work establishes a validated and scalable thermomechanical modeling framework that connects interpass temperature, material constitutive behavior, and process- induced stress and distortion. The results provide quantitative guidance for predictive process optimization, thermal-management design, and large-scale modeling of wire-arc and laser hot- wire DED systems.
Recommended Citation
Register, Matthew Allen, "Advancing wire arc directed energy deposition (arc-DED) modeling: the role of interpass temperature in process-property optimization" (2026). Theses and Dissertations. 6971.
https://scholarsjunction.msstate.edu/td/6971
