Simulation-assisted prediction of residual stress-induced failure during powder bed fusion of metals using a laser beam

Additive Manufacturing (AM) offers an alternative to conventional technologies for producing complex parts. Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M) is widely used for its high mechanical properties. However, thermally-driven stress-induced cracking is a challenge due to the uneven heat input. This study proposes a simulation-based approach to predict vulnerable regions in PBF-LB/M parts. Failure models for Inconel 718 were integrated into a PBF-LB/M process simulation, enabling the identification of critical locations prone to stress-induced fracture. Experimental validations confirmed the accuracy of a classical and an AM-adapted calibration method in predicting crack-prone zones. This approach enhances first-time-right manufacturing by enabling preemptive modifications.