Residual stress in laser-based directed energy deposition of aluminum alloy 2024: simulation and validation

Abstract Simulations of laser-based directed energy deposition metals have received increasing interest aimed at reducing the experimental effort to select proper processing condition for repair or overhaul actual components. One main issues be addressed is evaluation residual stress, which may lead part failure under nominal loading. In this frame and specifically relating aluminum alloys, few works been developed validated. This lack knowledge in paper: namely, approach simulate activation deposited metal discussed case single shifted a multiple depositions over substrate. The validation predicted stress made by comparison with resulting from X-ray diffraction.