Ali Kazemi Movahed
In-Process Mitigation of Residual Stress in Laser Powder Additive Manufacturing.
Rel. Abdollah Saboori. Politecnico di Torino, Corso di laurea magistrale in Ingegneria Meccanica (Mechanical Engineering), 2025
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Abstract
Residual stress is one of the most critical challenges in laser powder bed fusion (L-PBF), often leading to part distortion, cracking, and degraded mechanical performance. This thesis investigates the in-process mitigation of residual stress in Ti-6Al-4V components fabricated using L-PBF by exploring the role of scanning strategy. A series of experiments were conducted using different scanning strategies—including unidirectional, 45°, and 67° rotated patterns—under both continuous and discontinuous modes. The resulting residual stresses were measured using the X-ray diffraction (XRD) technique. Results showed that scanning strategy significantly affects stress development, with discontinuous 67° rotation yielding the lowest residual stress and continuous unidirectional scanning producing the highest.
To complement the experimental study, a thermal–mechanical simulation was developed in Abaqus using a sequentially coupled approach
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