Residual Stress Model in Laser Direct Deposition Based on Energy Equation

In this paper, 316 L stainless steel deposited samples were fabricated by direct layer deposition (DED) using both continuous-wave (CW) and pulsed-wave (PW) laser modes. Effects of laser modes on residual stress of deposited samples were investigated. On this basis, a mathematical model of thermal stress evolution during DED was established for the first time based on the energy equation. The variation law of thermal stress on the top of the substrate under multi-material and multi-process conditions was qualitatively predicted and the corresponding residual stress reduction mechanism has been studied using this model. Meanwhile, in situ thermal strain evolution is used to prove the correctness of the mathematical model. This model lays the foundation for predicting the thermal stress evolution and the magnitude of the residual stress of deposited samples under multi-material and process conditions during DED.