Residual stress evaluation in selective-laser-melting additively manufactured titanium (Ti-6Al-4V) and inconel 718 using the contour method and numerical simulation

Abstract Residual stresses play an important role for the structural integrity of engineering components. In this study residual stresses were determined in titanium alloy (Ti-6Al-4V) and Inconel 718 samples produced using selective-laser-melting (SLM) additive manufacturing. The contour method and a numerical simulation approach (inherent-strain-based method) were used to determine the residual stress distributions. The inherent-strain-based method reduces the computational time compared to weakly-coupled thermo-mechanical simulations. Results showed the presence of high tensile residual stresses at and near the surface of both titanium and Inconel alloys samples, whereas compressive residual stresses were seen at the center region. A good agreement was seen between the results obtained from contour method and the numerical simulation, particularly 1 mm below the surface of the samples.