Journal Article

IMPULSE-2026-00015

http://join2-wiki.gsi.de/foswiki/pub/Main/Artwork/join2_logo100x88.png Evaluating the predictive capabilities of part-scale residual stress simulations of PBF-LB/M up to crack formation by a comparison to neutron diffraction

Panzer, H. (First author) ; Landesberger, M.MLZ* ; Luzin, V. ; Rauner, D. ; Wolf, D. ; Zaeh, M. F.

2026
Elsevier Science Kidlington

Please use a persistent id in citations: doi:10.1016/j.engfracmech.2025.111713

Abstract: Additive manufacturing technologies have proven to be an excellent alternative to conventional production methods, especially when geometrically complex parts and low production quantities are aimed at. Specifically, powder bed fusion of metals using a laser beam (PBF-LB/M) additionally allows for the manufacturing of mechanically highly stressable parts. However, the heat input through the laser beam into the material and an irregular cooling during the processing result in the formation of high residual stresses. These lead to form deviations outside the specified tolerances and may accumulate to an extent, at which stress-induced cracking occurs. This emphasizes the need for an accurate prediction of the residual stresses during the PBF-LB/M process with the goal of a first-time-right additive manufacturing. In this study, three specimens exhibiting high residual stress formations during PBF-LB/M were manufactured from the nickel-based superalloy Inconel 718. Afterwards, the stresses were measured by means of neutron diffraction. The results provided the validation data for a subsequent finite element simulation, representing the build-up process on a part-scale, in which the data evaluation was conducted in accordance with the measurements for a high comparability. A comparison between the simulation and the neutron diffraction results of all three specimens showed a very good agreement of the normal stresses in all three coordinate directions, both for tensile and compressive stresses. The obtained results highlight the validity of the applied simplified part-scale simulation. The latter can, therefore, be utilized to increase the process understanding of residual stress and crack formations. It can also be used to enable process parameter modifications or geometry adaptions, aiming at a first-time-right additive manufacturing.

Keyword(s): Engineering, Industrial Materials and Processing (1st) ; Materials Science (2nd)

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Contributing Institute(s):

1. STRESSI (STRESSI)

Experiment(s):

1. STRESS-SPEC: Materials science diffractometer (SR3)

Appears in the scientific report 2026

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Database coverage:
; Clarivate Analytics Master Journal List ; Current Contents - Engineering, Computing and Technology ; Ebsco Academic Search ; Essential Science Indicators ; SCOPUS ; Science Citation Index Expanded ; Web of Science Core Collection

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