Simulation of residual stresses due to slm fabrication and correlation with directional fatigue behavior of AlSi10Mg

The selective laser melting process causes high thermal-induced residual stresses that may result in unwanted part distortion and may affect fatigue strength of the part. This study initially presents the fatigue behavior obtained by testing directional specimens of SLM AlSi10Mg in the as-built condition (i.e. no heat treatment after fabrication). Then, the SLM process of specimen fabrication is simulated using the inherent strain approach to determine residual stresses at the location and in the direction of fatigue crack initiation. A direct correlation of the computed residual stresses and the actual fatigue behavior provides qualitative insight into the simulation accuracy.