Abstract
Complex thermal histories in samples made by selective laser melting (SLM) lead to residual stress development, affecting the quality of the final product. SLM process parameters influence the melt temperature and the geometrical features of the molten pool. To investigate the effects of laser power and scan speed on transient temperature and residual stress evolutions and distributions during SLM process, a 3D finite element model has been established. Simulation results have shown that either increasing the laser power or reducing the scan speed causes a higher level of residual stress at the end of a scan track. To validate the simulation results, Ti–6Al–4V samples were made by SLM with varying process parameters and the sizes of melt pools on the top layer as well as the interlayer cracks and lack of fusions defects observed in the samples correlated well with the results from the finite element simulations.
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