Speaker
Description
The Laser Powder Bed Fusion (LPBF) process is a pivotal additive manufacturing technique that enables layer-by-layer fabrication of intricate metallic components with exceptional precision, material efficiency, and design flexibility. In the LPBF process, a high-intensity laser selectively melts and fuses the powder in each layer along with the layer beneath it. However, the localized heating inherent in the process generates significant temperature gradients, resulting in residual stresses that can compromise structural integrity, induce warping, and affect overall part performance. Addressing these challenges is crucial for ensuring the reliability of LPBF-fabricated parts, particularly for demanding applications in advanced industries. This study investigates the impact of laser path strategies on temperature distribution and residual stress formation in LPBF through thermo-mechanical simulations. A methodology based on the Julia programming language leverages a finite difference method (FDM) framework to simulate thermal and mechanical behaviour for different laser paths defined by G-Codes. The analysis spans multiple layers, enabling an evaluation of how scanning strategies influence heat dissipation and stress accumulation. Additionally, the effects of varying process parameters on residual stress development are examined. Benchmark geometries are employed to validate the model and explore the effects of laser path selection, timestep resolution, and scanning strategies on the results. By analysing diverse scanning patterns and their implications on heat flow and stress buildup, this research provides insights into optimizing LPBF processes. The findings aim to establish a deeper understanding of the relationship between laser paths, thermal gradients, and residual stress distributions. These insights are expected to contribute to the development of improved strategies for minimizing residual stresses, enhancing the quality and reliability of LPBF-fabricated components. The outcomes of this work offer practical guidelines for optimizing LPBF scanning strategies, advancing process control, and fostering broader adoption of additive manufacturing technologies in critical sectors. This research not only enhances the understanding of LPBF processes but also provides actionable strategies for improving part quality, supporting the growth of additive manufacturing in high-performance applications
