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<p>Residual stresses due to thermal accumulation from the laser powder bed fusion (LPBF) metal additive manufacturing (AM) process remains a critical challenge in the production of as-built components. They can lead to fabrication issues such as warping of components and build failures. Preventing these critical issues involve the understanding and optimization of machine parameters to improve part quality and process reliability. In this study, we present two case studies: a variable geometry build and a build of fatigue bars fabricated using Ti-6Al-4V. A thermomechanical finite element analysis (FEA) software, PanX, was implemented to predict the residual stresses of the two cases and the simulated results were validated against the results of the experimental builds. Results show that the thermal FEA was able to produce reliable thermal history with a symmetric error from a range of 2% to 14%. The mechanical FEA results accurately predicted large residual stresses which manifested in observed mechanical failure of some components in the variable geometry build. From this build, the FEA settings were used to evaluate the cross-transferability into the fatigue bars to evaluate modes of failure seen from the experiment. Unlike conventional approaches that rely on separate, time-intensive simulations for individual components, this work demonstrates a framework for simultaneous simulation of all parts within a build that captures inter-part thermal and mechanical interactions in a single model. Further insights into the LPBF manufacturing process can be made that enables a robust evaluation of the design stage to improve success and reliability of builds.</p>

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Part scale prediction of residual stress through thermomechanical modeling of additively manufactured Ti-6Al-4V

  • 期刊论文

  • 发表日期：

    2026年5月19日

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  • Emmanuel De Leon,
  • Rodolfo Villa,
  • Alex Riensche,
  • Benjamin D. Bevans,
  • Christopher Billings,
  • Jay Waterman,
  • Zahed Siddique,
  • Yingtao Liu

摘要

Residual stresses due to thermal accumulation from the laser powder bed fusion (LPBF) metal additive manufacturing (AM) process remains a critical challenge in the production of as-built components. They can lead to fabrication issues such as warping of components and build failures. Preventing these critical issues involve the understanding and optimization of machine parameters to improve part quality and process reliability. In this study, we present two case studies: a variable geometry build and a build of fatigue bars fabricated using Ti-6Al-4V. A thermomechanical finite element analysis (FEA) software, PanX, was implemented to predict the residual stresses of the two cases and the simulated results were validated against the results of the experimental builds. Results show that the thermal FEA was able to produce reliable thermal history with a symmetric error from a range of 2% to 14%. The mechanical FEA results accurately predicted large residual stresses which manifested in observed mechanical failure of some components in the variable geometry build. From this build, the FEA settings were used to evaluate the cross-transferability into the fatigue bars to evaluate modes of failure seen from the experiment. Unlike conventional approaches that rely on separate, time-intensive simulations for individual components, this work demonstrates a framework for simultaneous simulation of all parts within a build that captures inter-part thermal and mechanical interactions in a single model. Further insights into the LPBF manufacturing process can be made that enables a robust evaluation of the design stage to improve success and reliability of builds.