Additive manufacturing (AM) is a new and exciting production process that enables complex geometries with good design properties in a vast variety of applications. The parts are manufactured layer by layer from a precursor material, where the material is fused to a solid structure with the use of a powered heat source, e.g. laser. The substantial thermal gradient produced by the non-uniform heating gives rise to large residual stresses. To further improve the additive manufacturing process and to meet the growing demand of AM technology, it becomes important to understand the influence of the process parameters and material properties. This study will propose a coupled multi-physics analytical model to predict temperature and residual stresses in a Selective Laser Melting process (SLM), and later preform a sensitivity analysis of the process parameters and material properties in order to gain a fundamental understanding of the process and the interactions between process and performance.
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