Computational and Experimental Investigation of Residual Stress in Additively Manufactured Stainless Steel Components

Abstract

Additive manufacturing (AM) of stainless steel components offers design flexibility but induces residual stresses that compromise mechanical integrity. This work combines experimental techniques and finite element simulations to analyze residual stress in 316L stainless steel fabricated via selective laser melting (SLM). X-ray diffraction measurements were carried out to quantify residual stresses, while thermal-mechanical FEM simulations modeled the laser scanning process. Results indicated high tensile stresses along the build direction, exceeding 300 MPa in critical regions. Thermal gradient mechanisms were identified as primary stress drivers. Stress-relief heat treatments at 650 °C for 2 hours reduced residual stresses by nearly 70%, improving dimensional stability. Comparison of FEM predictions and experimental data showed strong agreement, validating the model. The integration of computational and experimental methods provides a comprehensive framework for predicting and mitigating residual stress in AM stainless steel components, facilitating their application in aerospace and biomedical industries.