Modelling and validation of hot isostatic pressing for additively manufactured FeSi-Inconel composites

Abstract This study explores the development of residual stresses in additively manufactured FeSi–Inconel 625 composites consolidated via hot isostatic pressing (HIP). Residual stress distributions were measured, and a finite element model (FEM) of the HIP process was developed to quantify the contribution of key mechanisms responsible for stress evolution. The model accounts for the mismatch in thermal expansion coefficients, thermal conductivities, and plastic deformation behaviour between the constituent materials. After validation against experimental data, the model was extended to simulate HIP consolidation of the individual materials. The results offer valuable insights into stress development during HIP and provide a framework for optimising the design and manufacturing of multi-material components.