Direct metal deposition (DMD) has gained increasing attention in the area of rapid manucooling rate, resulting in residual stresses and distortion. This paper presents a 3D sequentially coupled thermo-mechanical finite element model to predict residual stresses and deformations. The temperature distribution, thermal stress field and geometry deformation across domain are illustrated. The effect of deposition parameters on residual stress and deflections are also explored. A set of validation experiments for mechanical effects were conducted using laser displacement sensor. The comparisons between the simulated and experimental results show good agreement

Meeting Name

24th Annual International Solid Freeform Fabrication Symposium -- An Additive Manufacturing Conference (2013: Aug. 12-14, Austin, TX)


Mechanical and Aerospace Engineering

Research Center/Lab(s)

Intelligent Systems Center


This research was partially supported by Boeing Company. Support from Missouri S&T’s Intelligent Systems Center, Material Research Center, and Manufacturing Engineering program is also greatly appreciated.

Document Type

Article - Conference proceedings

Document Version

Final Version

File Type




Publication Date

14 Aug 2013

Included in

Manufacturing Commons