Thermo-structural Finite Element Analysis of Direct Laser Metal Deposited Thin-Walled Structures

Multilayer direct laser metal deposition is a fabrication process in which the parts are fabricated by creating a molten pool into which particles are injected. During fabrication, a complex thermal history is experienced in different regions of the build, depending on the process parameters and part geometry. The thermal history induces residual stress accumulation in the buildup, which is the main cause of cracking during the fabrication. The management of residual stress and the resulting distortion is a critical factor for the success of the process. A thermostructural finite element model (FEM) of the process is developed, and the analysis reveals different patterns of residual stress in the thin-walled structures depending on the deposition strategy and the geometry of the structures. The residual stress patterns obtained from finite element analysis (FEA) are in good agreement with the experimental results.