Numerical methods in predicting residual stresses in laser powder bed fusion developed parts – a scoping review

¹ Department of Industrial Engineering, Stellenbosch University, South Africa
² Research and Innovation Division, The South African Nuclear Energy Corporation (Necsa) SOC Limited, Pretoria, South Africa
³ Fraunhofer Institute for Ceramic Technologies and Systems IKTS, Dresden, Germany

^* Corresponding author: natashasacks@sun.ac.za

Abstract

The study reviews the numerical methods for predicting residual stresses in parts manufactured with additive manufacturing (AM) technique, such as laser powder bed fusion (L-PBF). L-PBF is a fast-growing technology with enormous potential for creating complex geometries with improved properties as compared to conventional processes. However, parts produced with L-PBF are susceptible to higher magnitudes of residual stresses, particularly tensile stresses as compared to compressive stresses, leading to geometrical distortions. While newly developed materials offer excellent properties and benefits to the industrial sector, the residual stresses that develop when parts are produced using the L-PBF process remain unexplored. The study evaluates three numerical simulation methods, such as thermomechanical modelling (TMM), inherent strain method (ISM), and multi-scale modelling (MSM) used to predict residual stresses in L-PBF parts. Each method has its advantages and limitations, and the best method depends on the specific application and available resources. The review highlights the potential benefits of numerical simulation methods for predicting residual stresses in L-PBF parts and compared to experimental results. Thus, the study recommends that future research should focus on improving the accuracy of numerical simulation methods for predicting residual stresses in L-PBF parts through refinement processes and exploring the impact of residual stresses on the L-PBF parts through detailed characterization.