Finite Element Modeling of Residual Stress Formation during Nanosecond Laser Ablation of Stainless Steel

Laser cleaning has recently gained attention as a non‐contact, precise, and environmentally friendly method for removing contaminants, oxides, or coatings from surfaces using controlled laser ablation. However, even at low fluence, where no visible damage is observed, thermal effects from nanosecond laser pulses can induce residual stress, potentially affecting the long‐term reliability of the material. This study introduces a finite element method model to predict residual stress formation in single‐pulse laser ablation of stainless steel, providing detailed insight into the localized thermomechanical response. The model captures individual pulse effects, including stress evolution, thermal expansion, and localized plastic deformation. Experimental validation via X‐ray diffraction is also performed. Based on this model, a parametric study is conducted to investigate the influence of pulse duration and fluence on residual stress development. The results reveal how thermal input parameters affect stress field formation and redistribution, even in the absence of visible material removal. These findings enhance understanding of stress generation in laser‐processed metals and offer a framework for predicting residual stress and identifying truly damage‐free thresholds in metallic substrates.