Residual stresses in selective laser sintering and selective laser melting

TLDR

This study investigates residual stresses in selective laser sintering and melting to better understand their origins and impact on additive manufacturing. A theoretical model predicts residual stress distributions, and experimental measurements of stress profiles were performed on test samples with varied process parameters. SLM parts exhibit large residual stresses with tensile zones at the top and bottom and a compressive core; stress magnitude and shape depend on material properties, part height, scanning strategy, and heating, and these findings can guide mitigation of stress‑related issues. Experiments used 316L stainless steel, so quantitative results may not transfer to other materials, though qualitative insights remain applicable.

Abstract

Purpose This paper presents an investigation into residual stresses in selective laser sintering (SLS) and selective laser melting (SLM), aiming at a better understanding of this phenomenon. Design/methodology/approach First, the origin of residual stresses is explored and a simple theoretical model is developed to predict residual stress distributions. Next, experimental methods are used to measure the residual stress profiles in a set of test samples produced with different process parameters. Findings Residual stresses are found to be very large in SLM parts. In general, the residual stress profile consists of two zones of large tensile stresses at the top and bottom of the part, and a large zone of intermediate compressive stress in between. The most important parameters determining the magnitude and shape of the residual stress profiles are the material properties, the sample and substrate height, the laser scanning strategy and the heating conditions. Research limitations/implications All experiments were conducted on parts produced from stainless steel powder (316L) and quantitative results cannot be simply extrapolated to other materials. However, most qualitative results can still be generalized. Originality/value This paper can serve as an aid in understanding the importance of residual stresses in SLS/SLM and other additive manufacturing processes involving a localized heat input. Some of the conclusions can be used to avoid problems associated with residual stresses.