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Delooze, Geoff
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document
Residual Stress in Additive Manufacture
Abstract
Powder bed fusion (PBF) and Directed Energy Deposition (DED) are the two widely used Additive Manufacturing (AM) technologies. Energy sources such as laser or electron beam are used for melting of powder or wire following the geometric information contained in a Computer-Aided-Design (CAD) file. In these processes, components or parts are built in a layer-by-layer manner until a fully dense 3D structure is achieved. High thermal gradients and multiple thermal cycles are usually observed in DED and PBF processes, which combined with the characteristic thermal contraction of metallic materials following solidification and cooling result in residual stress and shape distortion. Understanding of stress evolution in these processes is therefore highly desired for stress management and process improvement. This paper presents the predicted stresses occurring during DED and PBF of Ti-6Al-4V builds. The results provide an understanding of the evolution of stress during and after completion of the builds. Managing stress raisers is also discussed.