Residual Stress Modeling of Junction Structures Using Powder Injection Laser Cladding of Martensitic Stainless Steel on Low Alloyed Carbon Steel Substrate

Junction structures and rib constructions are utilized in various applications such as lightweight designs.As well as geometric challenges, using directed energy deposition metal additive manufacturing techniques to build intersections and junctions has the risk of having hydrostatic residual stress that can cause distortion or failure in the component.In this research, the residual stresses were measured computationally via a calibrated finite element analysis model for several junction structures, which the junction stresses evaluated as a function of deposition direction and order of operations.The path strategy significantly affects the mechanical and tensile properties of the junctions.This research needs to be extended to evaluate junctions for multi-layer scenarios.