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<p>Directed Energy Deposition (DED) offers significant advantages for additive manufacturing, including multi-material capability and high deposition rates. However, unavoidable residual stresses due to high cooling rates remain a critical challenge affecting part performance. Existing residual stress assessment methods, though well-developed, often prove impractical for industrial use due to their cost and complexity, particularly for frequent evaluation of stress relief heat treatment (SRHT) effectiveness. This study presents a rapid qualitative approach using wall-type buildups, where longitudinal slitting and slit opening measurement eliminate complex instrumentation. The work analyzes the influence of laser powder DED process parameters and geometric characteristics of Ti–6Al–4V buildups on residual stress distribution. Through combined numerical simulation and experimental validation, we demonstrate a good correlation between slit opening displacement and residual stress levels, enabling straightforward assessment. Key findings reveal that self-heating during deposition mitigates stresses, while extended dwell times induce logarithmic increase of slit openings. Most significantly, temperatures exceeding 550&#xa0;°C are essential for stress relaxation, with complete relief achieved at 650&#xa0;°C (120&#xa0;min) treatment. The proposed method offers industry a practical, cost-effective solution for optimizing SRHT parameters in DED-produced components.</p>

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A practical approach to evaluating stress relief heat treatments efficiency in directed energy deposition parts

  • 期刊论文

  • 发表日期：

    2025年11月17日

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  • Sergei Ivanov,
  • Anatoliy Blohin,
  • Artur Vildanov,
  • Aleksandr Ivanov

摘要

Directed Energy Deposition (DED) offers significant advantages for additive manufacturing, including multi-material capability and high deposition rates. However, unavoidable residual stresses due to high cooling rates remain a critical challenge affecting part performance. Existing residual stress assessment methods, though well-developed, often prove impractical for industrial use due to their cost and complexity, particularly for frequent evaluation of stress relief heat treatment (SRHT) effectiveness. This study presents a rapid qualitative approach using wall-type buildups, where longitudinal slitting and slit opening measurement eliminate complex instrumentation. The work analyzes the influence of laser powder DED process parameters and geometric characteristics of Ti–6Al–4V buildups on residual stress distribution. Through combined numerical simulation and experimental validation, we demonstrate a good correlation between slit opening displacement and residual stress levels, enabling straightforward assessment. Key findings reveal that self-heating during deposition mitigates stresses, while extended dwell times induce logarithmic increase of slit openings. Most significantly, temperatures exceeding 550 °C are essential for stress relaxation, with complete relief achieved at 650 °C (120 min) treatment. The proposed method offers industry a practical, cost-effective solution for optimizing SRHT parameters in DED-produced components.