Eigenstrain Analysis of Residual Stressed in Complex Shaped Additive Manufacturing Parts

This experiment proposal aims to address the challenges of residual stress analysis in laser powder bed fusion (LPBF) additive manufacturing. The proposal suggests using the eigenstrain theory and strain tomography technique to achieve 3D reconstruction of residual stresses in complex-shaped, discontinuously processed LPBF parts. High-energy synchrotron X-ray diffraction measurements will be conducted on an AlSi7Mg spiral tower sample, enabling the quantification of elastic strains necessary for eigenstrain determination. By reconstructing eigenstrain distributions, this study intends to calculate residual stresses accurately, thus eliminating the need for expensive process simulations. This innovative approach promises valuable insights into residual stress distributions, deformations, and post-processing scenarios, opening new possibilities for LPBF optimization and design.

本实验方案旨在解决激光粉末床熔融（laser powder bed fusion, LPBF）增材制造中的残余应力分析难题。该方案提出采用本征应变理论（eigenstrain theory）与应变断层扫描技术（strain tomography），对形状复杂且经非连续加工的LPBF构件实现残余应力的三维重建。研究将针对AlSi7Mg螺旋塔试样开展高能同步辐射X射线衍射（high-energy synchrotron X-ray diffraction）测试，以量化本征应变测定所需的弹性应变。通过重构本征应变分布，本研究拟精准计算残余应力，从而无需依赖成本高昂的工艺仿真。该创新方法有望为残余应力分布、构件变形及后处理场景提供宝贵见解，为LPBF工艺优化与构件设计开辟全新路径。