Residual stress and tensile anisotropy of hybrid wire arc additive-milling subtractive manufacturing

Abstract Hybrid wire arc additive-milling subtractive manufacturing (HWAAMS) is an effective method for the near net formation of complex structures by using the two processes alternately. The effects of milling width (ae) on the surface residual stress and the influence of milling thickness (t) on tensile anisotropy of the HWAAMS were studied using Al5Si aluminum alloy. The mean surface residual stress of HWAAMS in the middle dropped by 93 % relative to WAAM when the ae was 0.4 mm. The tensile elongation anisotropy could be controlled within 5 % when the t