Stress analysis in rapid manufacturing

A new Rapid Machining technique suitable to create components for functionality tests of prototypes, without using soft tools, was successfully developed. A high power laser is aimed at a substrate and a material powder is supplied to the interaction zone. 3D geometries were created by translating the substrate in XYZ direction. The energy source was a high power CO2 laser, the material powder under investigation was Stainless Steel SS304L (particle size 140 μm). Helium was used as a shield gas. The incident CO2 laser beam power was varied between 300 W and 400 W, with the laser beam intensity distributed in a donut mode of 600 μm diameter. Bulk stresses were investigated using x-ray facilities at Oak Ridge National Laboratory. The deposited material is single-phase austenitic steel. Pole figures reveal a preferred solidification in the direction of deposition