Design for AM: the impact of the shell feature on the residual stress in directed energy deposition components

ABSTRACT: Residual stress is inherent in Additive Manufacturing process due to the heat cycling of the material being deposited on the build plate. The manufacturing toolpath can have a considerable effect on the development of residual stress distribution within a component. This paper examines the impact of the shell feature to generate some design heuristics on whether to include it when residual stress is of concern. The stress feature did increase the residual stressed observed during printing but was mitigated by the cooling regime after the process was complete.