Effects of microstructure and inherent stress on residual stress induced during powder bed fusion with roller burnishing

A hybrid metal-additive manufacturing (AM) process that combines laser-based powder bed fusion (PBF-LB) with interlayer burnishing is investigated using a comprehensive modeling framework to provide new insights into how the inhomogeneous microstructure and residual stress from laser affect induced field evolves during burnishing. Researchers have recently studied changes in resulting similar processes, however, it was only hypothesized has some influence on stress. In addition, researchers numerically of burnishing/rolling parameters but neglected effects microstructure, thereby making homogeneous, isotropic assumptions. Such practice inhibits prediction microstructure-driven anisotropy can exist fused layer. This paper parametrically examines modeling, inherent mapping, environment temperature process. The demonstrated incorporates stresses emerge process, as well predicted subsequent simulation elucidate their individual combined influences burnishing-induced Findings reveal an PBF-LB introduces anisotropic distribution plastic strain along burnished surface; periodicity planar components treated surface coincides scan lines. Effects less significant, nonetheless observable. Elevated temperatures not reduce magnitude compressive also result variation component magnitudes lines hatch spaces. presented offers decoupled are distinguishable via experimental techniques. However, trends averaged through depth specimen, hardness after show good agreements, respectively, X-ray diffraction microindentation measurements documented literature. • First predictive model considering for post PBF Burnishing exhibits consistent w/PBF pattern. shown significantly variations due