Residual Stress Build-Up in Aluminum Parts Fabricated with SLM Technology Using the Bridge Curvature Method

Area of Science:

• Materials Science
• Manufacturing Engineering
• Additive Manufacturing

Background:

• Selective Laser Melting (SLM) of metals generates significant thermal gradients, leading to complex residual stress (RS) distributions.
• RS can cause part distortion and failure, necessitating accurate prediction and control methods.
• Existing methods like the Bridge Curvature Method (BCM) attempt to quantify RS but require refinement.

Purpose of the Study:

• To provide a novel perspective on RS build-up in AlSi10Mg parts fabricated via SLM.
• To experimentally and computationally assess the RS distribution in SLM-printed bridge samples.
• To propose improvements for the BCM based on experimental and simulation findings.

Main Methods:

• Utilized Selective Laser Melting (SLM) to print AlSi10Mg bridge samples.
• Employed the Hole Drilling Method (HDM) for experimental assessment of RS distribution.
• Conducted simulations using ANSYS and Simufact Additive for computational analysis.

Main Results:

• Characterized the RS distribution in SLM-printed AlSi10Mg bridge samples.
• Validated simulation tools (ANSYS, Simufact Additive) for RS prediction in SLM.
• Identified areas for improvement in the Bridge Curvature Method (BCM).

Conclusions:

• The study offers insights into RS build-up mechanisms in metallic 3D printing.
• The findings contribute to a better understanding of RS prediction tools for SLM.
• Recommendations are provided to enhance the BCM for improved precision and functionality of 3D-printed components.