Effects of substrate parameters on the residual stress and deflection of ti-6al-4v walls in additive manufacturing process

Given substrate parameters affect the heat transfer during additive manufacturing (AM) deposition process, the precision and residual stress of the component will also be affected. Such effect is an important aspect that should be considered but has not been reported. Thus, this paper presents a three-dimensional thermo-mechanical finite element model to study the effects of substrate parameters on the residual stress of Ti-6Al-4V walls during the AM process. The thermal and deflection histories and residual stress profile with different substrate parameters were investigated. Results show that the influence of the substrate height on the deflection, heat transfer and residual stress is most obvious, the length change has little influence on the deflection and stress distribution. The maximum deflection difference between the heights of 2.4 and 10.4 mm is 92.12%, the maximum deflection is reduced by 39.65% with the width increased from 15.4mm to 35.4mm. And the increased height is beneficial to the uniform of Z component residual stress but decrease uniformity of Y component residual stress.