Prediction of Residual Deformation and Stress of Laser Powder Bed Fusion Manufactured Ti-6Al-4V Lattice Structures Based on Inherent Strain Method

Abstract The development of additive manufacturing (AM) technology provides higher feasibility for designing and manufacturing lattice structures. However, the manufacturing process usually generates residual deformation and stress, and even produces cracking, thus affecting the performance of the parts. This work establishes a simulation model of the Ti-6Al-4V lattice structures during laser powder bed fusion (LPBF) based on the inherent strain method. Effects of geometric lattice parameters (inclination angle, rod diameter, rod length) on the residual deformation and stress are analyzed. Based on the simulation results, measures for improving the quality of the lattice structures are proposed. The proposed model and simulation results can provide theoretical references for designing and manufacturing the lattice structures during practical engineering applications of LPBF.