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Understanding processing parameters affecting residual stress in selective laser melting of Inconel 718 through numerical modeling

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Abstract

In this study, a thermal–elastic–plastic finite element model is proposed to investigate the effect of volume energy density on the temperature field, molten pool size, and residual stress distribution in the selective laser melting (SLM) process of Inconel 718 alloy. A temperature-dependent thermal–mechanical property of materials is considered, as well as the properties conversion between powder layer and solidified alloy. Within the scope of the study parameters, the simulated molten pool size increases with increasing volume energy density and exhibits linear growth relationship, which are validated by the experimental results and show a good agreement. In addition, five scanning strategies are adopted to study the effect of these scanning strategies on the residual stress distribution in this research. The results show that the residual stress distribution of SLM Inconel 718 specimen largely depends on the scanning strategy. Finally, to reveal the mechanism of residual stress formation, the restraint bar model is used to further analyze the formation mechanism of residual stress during the SLM process.

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Acknowledgments

This work is supported by the project to strengthen industrial development at the grass-roots level (Project No. TC160A310/19), Natural Science Foundation of Shanghai (Project No. 17ZR1409200), Shanghai Rising-star program (Project No. 18QB1400600), and Shanghai Materials Genome Institute No. 5 (Project No. 16DZ2260605).

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Authors and Affiliations

  1. Shanghai Engineering Research Center of 3D Printing Materials, Shanghai Research Institute of Materials, Shanghai, 200437, China

    Jia Song, Liang Zhang, Wenheng Wu, Beibei He, Xiaoqing Ni, Jiongkai Xu, Qiyun Yang, Tao Wang & Lin Lu

  2. Shanghai Key Laboratory of Advanced High-temperature Materials and Precision Forming, School of Materials Science and Engineering, Shanghai Jiao Tong University, Shanghai, 200240, China

    Guoliang Zhu

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  1. Jia Song
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  2. Liang Zhang
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  3. Wenheng Wu
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  4. Beibei He
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  5. Xiaoqing Ni
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  6. Jiongkai Xu
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  7. Guoliang Zhu
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  9. Tao Wang
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  10. Lin Lu
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Correspondence to Liang Zhang or Wenheng Wu.

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Song, J., Zhang, L., Wu, W. et al. Understanding processing parameters affecting residual stress in selective laser melting of Inconel 718 through numerical modeling. Journal of Materials Research 34, 1395–1404 (2019). https://doi.org/10.1557/jmr.2018.504

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  • DOI: https://doi.org/10.1557/jmr.2018.504

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