Finite Element Modelling of Micro-Rolling Assisted Directed Energy Deposition

The increasing applications of Directed Energy Deposition (DED) for near-net-shape components highlight the improvement of subpar build quality. Recently, experiments with in-situ micro-rolling hybridisation exhibited enhancements in quality. However, a thorough understanding of the associated thermo-mechanical mechanisms remains inadequately addressed due to measurement limitations. Consequently, fully coupled thermo-mechanical finite element models for the hybrid process have been developed, accommodating various application cases. Novel modelling approaches have been utilised for robust simulations, which yield insights into thermal history, plastic strain and stress evolution, and recrystallisation mechanisms. Therefore, the thesis provides a predictive tool for optimal utilisation of the hybrid process.