Finite element modelling for mitigation of residual stress and distortion in macro-scale powder bed fusion components

Powder bed fusion (PBF) has attracted significant attention in many applications due to its capability of fabricating complex and customized metal parts. However, the potential for high inherent residual stresses that produce distortion in additive manufacturing (AM) components prevents more widespread application of the AM technique. Efficient and accurate prediction of residual stress and distortion at component-level (macro-scale) is a complex task. Although process-level (meso-scale) thermo-mechanical simulations have resulted in accurate predictions for small-scale parts, the computational times (typically weeks) and memory requirements for application of such methods to component-level are prohibitive. The main goal of the current study therefore is to present an efficient and accurate finite element (FE) simulation method with detailed validation for PBF manufacture of a complex 3D Inconel 625 benchmark bridge component (macro-scale). The simulation results are successfully validated against the published benchmark experimental measurements from neutron diffraction, X-ray diffraction (XRD), contour method and coordinate measurement machine (CMM) by the National Institute of Standards and Technology (NIST) laboratory. A key additional novelty of the present work is the investigation of the effects of substrate removal and preheating on mitigation of residual stresses and distortions using the validated model. Ultimately, these results will guide the selection of optimal manufacturing protocols and integration of the FE-based AM modelling for industrial application with complex geometries. The ultimate aim of the present work is to facilitate fatigue life prediction of complex geometry AM components including residual stress effects, for example, conformally-cooled injection moulding dies (for different material than Inconel 625).