Application of process-integrated laser treatment for microstructure-induced distortion control in PBF-LB/M

Additive manufacturing of metal components by powder bed fusion using a laser beam (PBF-LB/M) is widely used for producing complex geometries. However, process-induced residual stresses, which can lead to distortion and cracking, thereby limiting geometric accuracy, remain a challenge. This work presents an integrated process-level approach to mitigate these effects by locally influencing the microstructure during fabrication through targeted laser-based treatment to reduce residual stresses. The approach is investigated experimentally using cantilever geometries, which serve as a benchmark for quantifying distortion caused by residual stresses. Based on the observed deformation behavior, the effectiveness of the proposed strategy in reducing process-induced distortion is assessed. The insights gained with these simple test geometries are subsequently applied to a real industrial component to evaluate the approach's broader applicability. A reduction in geometric deviation is observed when applying the proposed strategy, indicating its potential to mitigate distortion in practical PBF-LB/M applications. Overall, the study demonstrates that process-integrated laser treatment can influence the development of residual stress and associated distortion during PBF-LB/M. ... mehrThis helps enable broader, more reliable use of metal additive manufacturing in industrial applications.