Full-field validation of finite cell method computations on wire arc additive manufactured components

Wire arc additive manufacturing enables the production of components with high deposition rates and the incorporation of multiple materials. However, the manufactured components possess a wavy surface, which is a major difficulty when it comes to simulating the mechanical behavior of wire arc additively manufactured components and evaluation of experimental full-field measurements. In this work, the wavy surface of a thick-walled tube is measured with a portable 3D scanning technique first. Then, the surface contour is considered numerically using the finite cell method. There, hierarchic shape functions based on integrated Legendre polynomials are combined with a fictitious domain approach to simplify the discretization process. This enables a hierarchic p-refinement process to study the convergence of the reaction quantities and the surface strains under tension–torsion load. Throughout all considerations, uncertainties arising from multiple sources are assessed. This includes the material parameter identification, the geometry measurement, and the experimental analysis. When comparing experiment and numerical simulation, the in-plane surface strains are computed based on displacement data using radial basis functions as ansatz for global surface interpolation. It turns out that the finite cell method is a suitable numerical technique to consider the wavy surface encountered for additively manufactured components. The numerical results of the mechanical response of thick-walled tubes subjected to tension–torsion load demonstrate good agreement with real experimental data, particularly when employing higher-order polynomials. This agreement persists even under the consideration of the inherent uncertainties stemming from multiple sources, which are determined by Gaussian error propagation.