Finite element simulation of residual stress in direct metal laser sintering of AlSi10Mg built part: Effect of laser spot overlapping

Abstract

Direct metal laser sintering is a metal-based additive manufacturing process used to make the components directly from the metal powders in a layered fashion. A high-intensity laser beam is used to fuse the metal powders during the scanning of the powder bed. In this process rapid heating and solidification take place which leads to thermal stress in the build part that can affect the mechanical properties of the fabricated component. In the present work, a thermo-mechanical model was developed using a finite element approach to study the effect of laser spot overlapping on residual stress in the AlSi10Mg build part. From the simulation results, it was found that there was an increase in residual stress in the build part with increasing in laser spot overlapping.