Abstract
Process-dependent residual stresses are one of the main burdens to a widespread adoption of laser powder bed fusion technology in industry. Residual stresses are directly influenced by process parameters, such as laser path, laser power, and speed. In this work, the influence of various scan speed and laser power control strategies on residual stresses is investigated. A set of nine different laser scan patterns is printed by means of a selective laser melting process on a bare plate of nickel superalloy 625 (IN625). A finite element model is experimentally validated comparing the simulated melt pool areas with high-speed thermal camera in situ measurements. Finite element analysis is then used to evaluate residual stresses for the nine different laser scan control strategies, in order to identify the strategy which minimizes the residual stress magnitude. Numerical results show that a constant power density scan strategy appears the most effective to reduce residual stresses in the considered domain.
Highlights
Laser powder bed fusion (LPBF) or selective laser melting (SLM) is an additive manufacturing (AM) technology where freeform parts are produced by means of a layer-by-layer process
Homogeneous models are mainly adopted to study the influence of different scan strategies and other process parameters either on melt pool shapes and cooling rates [13,14,15,16,17,18,19,20,21] or on residual stresses [22,23,24,25,26], and they are generally implemented using weakly coupled thermo-mechanical finite element analysis (FEA)
The results reported in the present work give a new insight into the nine advanced laser scan strategies studying their influence on residual stress as well
Summary
Laser powder bed fusion (LPBF) or selective laser melting (SLM) is an additive manufacturing (AM) technology where freeform parts are produced by means of a layer-by-layer process. Numerical simulations can help to evaluate the effects of laser power and scan speed control strategies on residual stresses.
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