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.