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<p>Selective laser melting is a widely used method in the metal additive manufacturing industry, allowing for complex structures with less waste and more design flexibility via customization. In the present work, the impeller part is fabricated with a unidirectional orientation. SLM-made SS316L’s microstructure and flaws are studied with an optical microscope, an SEM/EDX, hardness tests, and a residual stress measurement. Validation of residual stresses was carried out using ANSYS Additive Print software combined with expert knowledge of Finite Element Methods. In the upper part of the vane, the highest residual stresses were observed at 163&#xa0;MPa in experiments and 188&#xa0;MPa in simulations, with a difference of 20%. Greater density, homogeneity, and absence of porosity characterise the final product, which is harder than cast components. Residual stresses are well under the yield limits of the base material, with a safety factor of 1.13.</p> Graphical abstract <p></p>

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Residual stresses and microstructure analysis of SS316L impeller part using selective laser melting: simulation and experimental validation

  • 期刊论文

  • 发表日期：

    2025年7月3日

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  • K. Veera Raghavulu,
  • Panchagnula Jayaprakash Sharma,
  • Panchagnula Kishore Kumar,
  • N. Gangisetty,
  • Harinadh Vemanaboina,
  • Chander Prakash

摘要

Selective laser melting is a widely used method in the metal additive manufacturing industry, allowing for complex structures with less waste and more design flexibility via customization. In the present work, the impeller part is fabricated with a unidirectional orientation. SLM-made SS316L’s microstructure and flaws are studied with an optical microscope, an SEM/EDX, hardness tests, and a residual stress measurement. Validation of residual stresses was carried out using ANSYS Additive Print software combined with expert knowledge of Finite Element Methods. In the upper part of the vane, the highest residual stresses were observed at 163 MPa in experiments and 188 MPa in simulations, with a difference of 20%. Greater density, homogeneity, and absence of porosity characterise the final product, which is harder than cast components. Residual stresses are well under the yield limits of the base material, with a safety factor of 1.13.

Graphical abstract