Abstract
A computational modeling technique to simulate residual stress formation during the
Electron Beam Melting (EBM) process within the Additive Manufacturing (AM) tech-
nologies for Inconel 718 is presented in this paper. The EBM process has demonstrated
a high potential to fabricate components with complex geometries, but the resulting
components are in
uenced by the thermal cycles observed during the manufacturing
process. When processing nickel based superalloys, very high temperatures ( 1000C)
are observed in the powder bed, base plate, and build. These high temperatures, when
combined with substrate adherence, can result in warping of the base plate and a ect
the nal component by causing defects. It is important to have an understanding of
the thermo-mechanical response of the entire system, that is, its mechanical behavior
towards thermal loading occurring during the EBM process prior to manufacturing a
component. Therefore, computational models to predict the response of the system dur-
ing the EBM process will aid in eliminating the undesired process conditions, a-priori,
in order to fabricate the optimum component. Such a comprehensive computational
modeling approach demonstrated to analyze the warping of the base plate, stress and
plastic strain accumulation within the material, and thermal cycles in the system during
di erent stages of the EBM process.
