An analytical method for predicting residual stress distribution in selective laser melted/sintered alloys

Dibakor Boruah, Xiang Zhang, Matthew Doré

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    Residual stresses that build up during selective laser melting or sintering (SLM/SLS) process can influence the dimensional accuracy, mechanical properties and overall in-service performance of SLM/SLS parts. Therefore, it is crucial to understand, predict and effectively control the residual stress distribution in a part. The present study aims at developing an analytical model to predict the distribution of residual stresses in the part-substrate system. The proposed model demonstrates how residual stresses build up in the substrate and previously deposited layers are related to the stress induced by a newly deposited layer, considering the stress and moment equilibrium requirements. The model has been validated by published experimental measurements and verified with existing analytical/numerical models. The outcomes of the study suggest that the proposed analytical model is applicable for quick estimation of residual stress distribution and the order of magnitude. Also, it provides an evaluation tool for SLM/SLS process parameter design.
    Original languageEnglish
    Title of host publicationEuropean Conference on Residual Stresses 2018 (ECRS-10)
    Subtitle of host publicationMaterials Research Proceedings
    EditorsMarc Seefeldt
    PublisherMaterials Research Forum LLC
    Number of pages6
    ISBN (Electronic)978-1-945291-89-0
    ISBN (Print)978-1-945291-88-3
    Publication statusPublished - 5 Oct 2018
    Event10th European Conference on Residual Stresses - KU Leuven, Leuven, Belgium
    Duration: 11 Sept 201814 Sept 2018
    Conference number: 10


    Conference10th European Conference on Residual Stresses
    Abbreviated titleECRS10
    Internet address

    Bibliographical note

    Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.


    • Residual Stress
    • Analytical Modelling
    • Selective Laser Melting
    • Additive Manufacturing
    • Selective Laser Sintering

    ASJC Scopus subject areas

    • Engineering(all)
    • Materials Science(all)


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