Correlation of meltpool characteristics and residual stresses at high laser intensity for metal lpbf process

Selective Laser Melting (SLM) commonly referred as Metal Laser Powder Bed Fusion (LPBF) processes, proved in the last decade to be suitable for the manufacturing of complex metallic components. In order to fulfil industrial needs from various industries (e.g. aerospace, tooling, energy production, medical), Machine manufacturers have increased the productivity of the LPBF-process mainly by increasing the number and maximum power of lasers. However, this strategy also affects the magnitude of residual stresses generated in the consolidated material. This study analyses the residual stresses in SS316L components by XRD measurement, where a correlation to the meltpool dimensions could be found and verified for different laser power and scan speeds. The results provide fundamentals to assess the gain in productivity, and to establish generic guidelines for the optimization of residual stresses at high laser power.