AN INVESTIGATING DEFORMATION AND RESIDUAL STRESS IN OVERHANG STRUCTURES PRODUCED BY LASER POWDER BED FUSION: AN EXPERIMENTAL AND THERMO-MECHANICAL SIMULATION STUDY
DOI:
https://doi.org/10.23055/ijietap.2026.33.5.11197Abstract
In the field of laser powder bed fusion (L-PBF), overhang structures are prone to warping and residual stresses due to inadequate thermal dissipation and mechanical constraints. While contour scanning is a widely adopted technique to improve surface quality, its effects on stress and deformation dynamics remain insufficiently understood. This study systematically investigates the impact of contour scanning on overhang parts with angles ranging from 45° to 60°, employing a combination of experimental analyses and thermo-mechanical simulations. Overhang samples made of 316L stainless steel were produced using an SLM 125HL system. Experimental findings demonstrate a direct correlation between increasing overhang angles and the severity of deformation, prevalence of surface defects, and occurrences of melt-through. To further explore these phenomena, a coupled finite element model was developed to simulate the evolution of stress during contour scanning, integrating Goldak’s heat source model alongside temperature-dependent material properties. The results indicate that localized thermal gradients generated around the contour paths induce asymmetric warping and heightened stress concentrations at the free ends of the overhang structures. Notably, the simulation results align closely with experimental observations, revealing a cumulative layer-by-layer build-up of residual stresses that is influenced by the scanning history. These findings illuminate the significant role of contour scanning in residual stress formation and provide essential guidance for the optimization of processing parameters in the fabrication of unsupported overhang structures via L-PBF.
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