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Residual stresses in selective laser sintering and selective laser melting

Residual stresses in selective laser sintering and selective laser melting 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. http://www.deepdyve.com/assets/images/DeepDyve-Logo-lg.png Rapid Prototyping Journal Emerald Publishing

Residual stresses in selective laser sintering and selective laser melting

Rapid Prototyping Journal , Volume 12 (5): 12 – Oct 1, 2006

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References (11)

Publisher
Emerald Publishing
Copyright
Copyright © 2006 Emerald Group Publishing Limited. All rights reserved.
ISSN
1355-2546
DOI
10.1108/13552540610707013
Publisher site
See Article on Publisher Site

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.

Journal

Rapid Prototyping JournalEmerald Publishing

Published: Oct 1, 2006

Keywords: Sintering; Lasers; Stress (materials)

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