Residual Stresses Control in Additive Manufacturing

Residual stresses are one of the primary causes for failure parts or systems in metal additive manufacturing (AM), since they easily induce crack propagation and structural distortion. Although formation residual has been extensively studied, core factors steering their development AM have not completely uncovered. To date, several strategies based on reducing thermal gradients developed to mitigate manifestation AM; however, how choose optimal processing plan is still unclear designers. In this regard, concept yield temperature, related deformation mechanical constraint, plays a crucial role controlling stresses, but it duly investigated, corresponding approach control also yet lacking. undertake such study, three-bar model firstly used illustrate mechanism stress its key causes. Next, an experimentally calibrated thermomechanical finite element analyze sensitivity scan pattern, preheating, energy density, part geometry size, as well substrate constraints. Based numerical results obtained from analysis, recommendations minimize during process provided.