Coupled experimental and computational study of residual stresses in additively manufactured Ti-6Al-4V components

The production of metallic parts via laser-powder bed fusion (L-PBF) additive manufacturing is rapidly growing. To use components produced via L-PBF in safety-critical applications, a high degree of confidence is required in their quality. This qualification can be supported by means of a validated thermomechanical model capable of predicting the final residual stress state and subsequent performance. In this work, we use high-energy X-ray diffraction to determine a three-dimensional residual strain and stress state in a Ti-6Al-4V L-PBF component. The experimental results are used to provide validation of simulations, showing strong quantitative agreement.