Residual Stress Build-Up in Aluminum Parts Fabricated with SLM Technology Using the Bridge Curvature Method

In metal 3D printing with Selective Laser Melting (SLM) technology, due to large thermal gradients, the residual stress (RS) distribution is complicated to predict and control. RS can distort the shape of the components, causing severe failures in fabrication or functionality. Thus, several research papers have attempted to quantify the RS by designing geometries that distort in a predictable manner, including the Bridge Curvature Method (BCM). Being different from the existing literature, this paper provides a new perspective of the RS build-up in aluminum parts produced with SLM using a combination of experiments and simulations. In particular, the bridge samples are printed with AlSi10Mg, of which the printing process and the RS distribution are experimentally assessed with the Hole Drilling Method (HDM) and simulated using ANSYS and Simufact Additive. Subsequently, on the basis of the findings, suggestions for improvements to the BCM are made. Throughout the assessment of BCM, readers can gain insights on how RS is built-up in metallic 3D-printed components, some available tools, and their suitability for RS prediction. These are essential for practitioners to improve the precision and functionality of SLM parts should any post-subtractive or additive manufacturing processes be employed.

Influence of Heat Treatment of Steel AISI316L Produced by the Selective Laser Melting Method on the Properties of Welded Joint

This work is focused on the influence of heat treatment of a part produced by the SLM (selective laser melting) method of stainless steel, 316L. Two heat treatment regimens were tested and compared with the state without heat treatment. Subsequently, TIG (tungsten inert gas) welds were created on the base materials processed in this way. All welds were subjected to mechanical tests and microstructural analysis. The tensile test was performed both for the welded joint and for the base material in the transverse and longitudinal directions. The tensile strength values of the samples with the welded joint were compared with the values required for the base material, 316L forged steel (1.4404). Microstructural analysis revealed significant differences between samples with and without heat treatment. The results of these tests are supported by SEM analysis. EDAX (energy dispersive analysis of X-rays) semiquantitative analysis confirmed the presence of ultra-fine pores in the structure. The results of mechanical tests show that the solution annealing at 1040 °C for 0.5 h gives better results than the same heat treatment with a duration of 2 h.