Assessing Residual Stresses in WAAM Manufactured Components Using the Magnetic Barkhausen Noise Technique
Name: FELIPE SOARES FUNDÃO
Publication date: 12/02/2026
Examining board:
Name |
Role |
|---|---|
| JUAN MANUEL PARDAL | Examinador Externo |
| MARCELO CAMARGO SEVERO DE MACEDO | Presidente |
| OLGA LISKEVYCH | Coorientador |
| SÉRGIO SOUTO MAIOR TAVARES | Examinador Externo |
Summary: Additive manufacturing (AM) has emerged as an efficient alternative to traditional manufacturing methods, enabling the production of complex parts with reduced material waste. Among the available processes, Wire Arc Additive Manufacturing
(WAAM), a type of Directed Energy Deposition (DED), uses a welding arc as an energy source and a metallic wire as feedstock. However, intense thermal cycles and rapid solidification can generate significant residual stresses, compromising the structural
integrity of the components. This study investigated residual stresses in WAAM produced parts using a 1.2 mm ER70S-6 wire on an AISI 1020 substrate through Magnetic Barkhausen Noise (MBN). This magnetic technique is sensitive to induced stresses and allows for fast measurements without special sample preparation. The analysis focused on two main parameters: voltage and frequency. The results demonstrated that frequency directly influences the penetration depth of the magnetic field and the intensity of the Barkhausen effect, affecting the MBN response. Higher frequencies reduced penetration depth and increased the root mean square (RMS) values of the signal. Residual stress distribution maps were compared with finite element simulations and hole-drilling measurements from previous studies, showing good correlation. These findings confirm the feasibility of MBN as a quality control tool for DED-manufactured components, provided that test parameters and possible microstructural transformations are carefully considered.
Keywords: additive manufacturing (AM), directed energy deposition (DED), wire arc additive manufacturing (WAAM), residual stresses, magnetic Barkhausen noise (MBN), frequency, penetration depth.
