Distortion minimization of laser‐processed components through control of laser scanning patterns

Abstract

Residual thermal stresses and distortion are frequently present in the parts built using a layer‐by‐layer solid freeform fabrication techniques assisted with a moving laser source. This study uses finite element analysis to investigate the effect of laser scanning patterns on residual thermal stresses and distortion. It is shown that the out‐of‐plane distortion of a layer, processed by a moving laser beam can be minimized with a proper selection of the laser scanning pattern. A scanning pattern having changes in its scanning direction frequently by 90° at every turn can lead to the cancellation of concave upward and downward distortions. As a result of this cancellation, very small distortion is present in the laser processed plate. It is also found that distortion is mainly caused by transient thermal stresses rather than residual thermal stresses.