Abstract:
Selective laser melting (SLM) is one of the most well-known additive manufacturing
methods available for the fabrication of functional parts from metal powders. Although SLM is now
an established metal additive manufacturing technique, its widespread application in industry is
still hindered by inherent phenomena, one of which is high residual stresses. Some of the e ects of
residual stresses–such as warping and thermal stress-related cracking–cannot be corrected by post
processing. Therefore, establishing input process parameter combinations that result in the least
residual stress magnitudes and related distortions and/or cracking is critical. This paper presents the
influence of laser power, scanning speed, and layer thickness on residual stresses, distortions and
achievable density for maraging steel 300 steel parts in order to establish the most optimum input
parameter combinations. An analysis of the interdependence between process outcomes shows that
high residual stress magnitudes lead to high dimensional distortions in the finished parts, whilst
porous parts su er relatively lower residual stresses and associated distortions.
