New scanning strategy to reduce warpage in additive manufacturing

This paper proposes a novel geometric based scanning strategy adopted in the selective laser melting (SLM) manufacturing technology aimed at reducing the level of residual stresses generated during the build-up process. A set of computer simulations of the build, based on different scans strategies, including temperature dependent material properties, and a moving heat flux, were performed. The research novelty explores intermittent scan strategies in order to analyze the effect of reduction on heat concentration on the residual stress and deformation. Coupled thermal-structural computations revealed a significant stress and warpage reduction on the proposed scanning scheme. Different powder material properties were investigated and the computational model was validated against published numerical and experimental studies.