Experimental Study of Residual Stresses in Metal Parts Obtained by Selective Laser Melting

High local temperature gradients occur at additive manufacturing by selective laser melting of powder. This gives rise to undesirable residual stresses, deformations, and cracks. To understand how to control the formation of the residual stresses, a reliable method is necessary for measuring their distribution in the fabricated part. It is proposed to cut the part into thin plates and to reconstruct the residual stresses from the measured deformation of the plates. This method is tested on beams with square cross-section built from stainless steel. The beams were cut by electrical discharge machining and chemically etched. The obtained stress profile in vertical transversal direction slightly increases from the top to the bottom of the beam. This dependency is confirmed by numerical modeling. The measured stress profile agrees with the known results by other authors.