Recoater-Induced Distortions and Build Failures in Selective Laser Melting of Thin-Walled Ti6Al4V Parts

Additively manufactured thin-walled structures through selective laser melting (SLM) are of great interest in achieving carbon-neutral industrial manufacturing. However, residual stresses and warpages as well recoater crashes often occur SLM, leading to the build failure parts, especially for large-scale lightweight geometries. The challenge this work consists investigating how affects warpage (sometimes) causes different Ti6Al4V parts (wall thickness 1.0 mm). All these printed on same platform using a commercial SLM machine. After loose powder removal before cutting operation, 3D-scanner is used obtain actual each component. Next, an in-house coupled thermo-mechanical finite element model suitable numerical simulation process enhanced consider effects. This framework calibrated predict measured by 3D-scanner. combination predictions with experimental observations facilitates comprehensive understanding mechanical behavior components mechanism due recoater. findings show that use higher energy input larger responsible crashes. Finally, potential solutions mitigate assessed validated model.