Predictive Modeling and Contour Method Validation of Residual Stresses in Notched PBF-LB/M/Ti6Al4V Components Using the Inherent Strain Method

Residual stresses and distortions are critical challenges in laser beam powder bed fusion (PBF-LB) of Ti6Al4V components (PBF-LB/M/Ti6Al4V), impacting structural integrity and dimensional accuracy. This study assesses the inherent strain method (ISM) as a computationally efficient alternative to full thermomechanical simulations for predicting these effects. By integrating ISM with experimental validation via the contour method, the research provides specific insights into stress distribution patterns in geometries featuring stress concentrators such as notches. Results demonstrate a strong correlation between simulation and experimental data, particularly at the mid-height regions. Quantitatively, the orthotropic ISM successfully predicted the peak residual stress at 1101.4 MPa, showing excellent agreement within a 4% error margin against the experimental maximum of 1144 MPa captured via the contour method. These findings underscore how ISM can be effectively applied to practical engineering components to predict high-stress zones, enabling the design of distortion-compensated parts without the high computational cost of traditional models. Ultimately, this method facilitates more robust process optimization and enhances the quality and reliability of Ti6Al4V components manufactured via PBF-LB.