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<p>The overhang feature, frequently encountered in complex geometries, presents considerable challenges in laser powder bed fusion (L-PBF), including dross accumulation, powder adhesion, and warping—factors that collectively compromise component quality. This study examines the influence of overhang angle and wall thickness on warping deformation during the layer-by-layer L-PBF process for a Ni-based superalloy (GH3625). A simulation-predicted constraint window for geometric parameters is proposed to optimize manufacturability. For a representative overhang with a 45° inclination and 1.5&#xa0;mm wall thickness, warping deformation is primarily localized on the downward-facing surface of the overhang, with a maximum displacement of around 25&#xa0;μm. In this simulation, the build plate was modeled as fully constrained (fixed), and residual stress evolution was accounted for through a thermo-elasto-plastic material model. This setup reflects typical boundary conditions in L-PBF processes and enables realistic prediction of deformation behavior during layer-by-layer fabrication. This deformation stabilizes after approximately 50% of the printing process is completed. Thermal stress analysis indicates that stress concentrations are higher in the solid regions compared to the overhang edges. Upon cooling, these stresses transition to compressive in the bulk regions, whereas tensile residual stresses remain in the overhang areas. As the overhang angle decreases, warping deformation in the Z-direction increases significantly (exceeding 0.5&#xa0;mm at 25°). Similarly, increasing the wall thickness leads to more severe deformation, with the thickest walls showing the largest warping.</p>

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Effect of overhanging structure parameters on warping deformation and forming quality in the laser powder bed fusion (L-PBF) process

  • 期刊论文

  • 发表日期：

    2026年2月3日

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  • Hai Tao Wang,
  • Guo Zheng Quan,
  • Wen Qiang Liu,
  • Yi Hai He,
  • Sheng Lei

摘要

The overhang feature, frequently encountered in complex geometries, presents considerable challenges in laser powder bed fusion (L-PBF), including dross accumulation, powder adhesion, and warping—factors that collectively compromise component quality. This study examines the influence of overhang angle and wall thickness on warping deformation during the layer-by-layer L-PBF process for a Ni-based superalloy (GH3625). A simulation-predicted constraint window for geometric parameters is proposed to optimize manufacturability. For a representative overhang with a 45° inclination and 1.5 mm wall thickness, warping deformation is primarily localized on the downward-facing surface of the overhang, with a maximum displacement of around 25 μm. In this simulation, the build plate was modeled as fully constrained (fixed), and residual stress evolution was accounted for through a thermo-elasto-plastic material model. This setup reflects typical boundary conditions in L-PBF processes and enables realistic prediction of deformation behavior during layer-by-layer fabrication. This deformation stabilizes after approximately 50% of the printing process is completed. Thermal stress analysis indicates that stress concentrations are higher in the solid regions compared to the overhang edges. Upon cooling, these stresses transition to compressive in the bulk regions, whereas tensile residual stresses remain in the overhang areas. As the overhang angle decreases, warping deformation in the Z-direction increases significantly (exceeding 0.5 mm at 25°). Similarly, increasing the wall thickness leads to more severe deformation, with the thickest walls showing the largest warping.