Quantifying Residual Stresses Generated by Laser-Powder Bed Fusion of Metallic Samples

We use numerical modeling to predict residual stresses and deformations of thin metallic structures manufactured by laser-powder bed fusion. The effect of L-PBF process on residual deformations of thin quasi-2D structures is expected to be more substantial and complex than for thicker/bulk or axisymmetric components. Two types of geometries are considered: a thin horizontal plate for residual force measurements and thin vertical plates for residual deformations and support removal experiments. In both cases knowledge of the initially deformed shape and internal residual stresses will affect experimental interpretation. The numerical scheme used (ANSYS Additive Suite) involves weakly coupled thermomechanical simulations in a commercially available finite element package. It is shown that the simulations are in qualitative and general quantitative agreement with the experimental measurements within this numerical framework. Additionally, it is shown that the provided numerical framework can be used to predict the effect of support removal sequence on the final geometry of thin metallic structures.