An analytical method for predicting residual stress distribution in selective laser melted/sintered alloys

Residual stresses that build up during selective laser melting or sintering (SLM/SLS) process can influence the dimensional accuracy, mechanical properties and in-service performance of SLM/SLS parts. Therefore, it is crucial to understand, predict and effectively control residual stresses in a part. The present study aims at developing an analytical model to predict the through-thickness distribution of residual stresses in an SLM part-substrate system. The proposed model demonstrates how residual stresses built up in the substrate and previously deposited layers are related to the stress induced by a newly deposited layer, based on the stress and moment equilibrium requirements. The model has been validated by published experimental measurements and verified with existing analytical/numerical models. The outcomes of the study suggest that the proposed analytical model can be used for quick estimation of residual stress distribution and the order of magnitude