Residual Stresses in Alloy IN718 Produced Through Modulated Laser Powder Bed Fusion

Abstract

Background: Laser powder bed fusion (L-PBF) additive manufacturing (AM) is used for building metallic parts layer-by-layer and often generates non-uniform thermal gradients between layers during fabrication, resulting in the development of residual stresses when parts are cooled down. Objective: The impact of modulated laser used during the L-PBF process on residual stresses in Inconel 718 (IN718) material was investigated. The impact of build directions on residual stress is also determined. Methods: The contour method is employed to measure the full-field residual stress component on the cross-section of samples. A complementary residual stress measurement method, incremental hole drilling, was employed for obtaining in-plane residual stress components. Results: The results show that the residual stress distribution is sensitive to the build direction, with a higher magnitude of residual stress in the direction of build than that in the transverse direction. Multiple measurements with the same manufacturing parameters show good repeatability. Conclusion: Residual stresses in the as-built parts are significant and hence a further consideration regarding relieving residual stresses is required when post-thermal treatments are developed.