Abstract
This article introduces an innovative study on residual stress analysis in Laser Powder Bed Fusion (LPBF) fabricated materials, focusing on an Al-3Ni-Ti-0.8Zr sample. By leveraging Swadener’s theoretical approach alongside nanoindentation techniques, the research offers a cost-effective and easily applicable method for mapping residual stress patterns, distinguishing itself from more expensive and complex techniques like X-ray diffraction or destructive methods such as contour or drilling. The investigation correlates residual stress patterns with critical mechanical properties, including yield strength 265.03 MPa and ultimate tensile strength up to 347.5 MPa, thereby demonstrating the significant influence of LPBF process parameters on material characteristics. The findings provide initial validation of this accessible methodology, emphasizing its potential as a tool for understanding and mitigating residual stresses. As an ongoing endeavor, future work will expand upon these insights through broader data collection, rigorous validation, and comparative analyses with other stress detection techniques. This study marks a significant advancement in additive manufacturing research, aiming to optimize LPBF processes and improve material performance by offering a more straightforward yet effective alternative to traditional stress analysis methods.
