Process Parameters Optimisation for Mitigating Residual Stress in Dual-Laser Beam Powder Bed Fusion Additive Manufacturing

Laser beam powder bed fusion (PBF-LB) additive manufacturing (AM) is an advanced technology that manufactures metal components in a layer-by-layer manner. The thermal residual stress (RS) induced by the repeated heating–melting–cooling–solidification processes of AM considered to limit wider uptake PBF-LB. A dual-laser PBF-LB strategy, with additional auxiliary laser and reduced power, working same simultaneously, was recently proposed lower RS within manufactured components. To provide insights into optimum configurations process parameters for PBF-LB, this study three different coordinated heating strategies (i.e., parallel heating, post-heating, preheating) heat source. temperature fields Ti-6Al-4V parameters, were computationally investigated optimized thermo-mechanically coupled 3D models. Compared single post-heating proved as effective approaches reduce RS. Among these, preheating scanning predicted be more mitigating RS, i.e., up 10.41% reduction, compared scanning. This work could beneficial improve mechanical properties additively