Process Maps for Controlling Residual Stress and Melt Pool Size in Laser-Based SFF Processes 200

Thermal control of solid freeform fabrication processes is critical for obtaining consistent build conditions and in limiting residual stress-induced tolerance losses. In this paper, thermomechanical models are presented for the building of thin-walled structures by laser-based SFF processes. The simulations are used to develop two non-dimensional plots (termed process maps) that quantify the effects of changes in wall height, laser power, deposition speed and part preheating on melt pool size (for consistent build conditions) and thermal gradients (for limiting residual stresses). Mechanical simulations are used to demonstrate the link between thermal gradients and maximum final residual stresses. Models are applied to the Laser Engineered Net Shaping (LENS) process; however, the general approach, insights and conclusions are applicable to most SFF processes involving a moving heat source. The two process maps described herein can be used together to determine optimal process variables for obtaining consistent melt pool length while limiting residual stress in the part. Results from the residual stress simulations also identify two important mechanisms for reducing residual stresses and quantify maximum stress reductions that can be achieved through manipulation of all process variables.