Study of the Role of Geometry on the Residual Stresses Development in Laser‐Based Powder Bed Fusion As‐Built Ti‐6Al‐4V Components Using Finite Element Simulations

A significant problem associated with additively manufactured components is the development of high residual stresses, which impact their structural integrity and performance. Measuring these residual stresses in components with curved surfaces is often challenging. Hence, in this study, we employ a sequential thermo‐mechanical finite element analysis as an alternative approach to investigate the development of residual stresses across Ti‐6Al‐4V components with varying curvature: simple wall, open cylinder, and dome. Part‐scale simulations using a layer bundling approach were performed, and the model was validated for thin walls, using experimentally determined stresses from synchrotron X‐ray radiation coupled with a conical slit cell. It is shown that the geometry of the components strongly influences the local thermal dissipation, which in turn affects the nature of the developed residual stresses. Furthermore, we show that the process of cutting the components from the base plate results in a relatively local redistribution of the residual stresses. This work provides a deeper understanding of the relationship between geometrical aspects and the evolution of residual stress in Ti‐6Al‐4V components, which helps optimise the additive manufacturing process and postbuild heat treatments according to specific requirements.