Prediction and Experimental Verification of Distortion due to Residual Stresses in a Ti-6Al-4V Control Arm Plate

Abstract

This study evaluates the distortion in an SLM-printed Ti-6Al-4V control arm plate of a double-wishbone suspension linkage. Temperature gradients are a common observation in selective laser melting (SLM). The development of residual stresses can lead to performance-based concerns due to the distortions emerging in part. Despite these shortcomings, SLM has often been employed in manufacturing high-end structural components under its ability to produce complex geometries. A thermomechanical simulation predicts the residual stresses developed in part and the distortions generated by those stresses. The simulation model is validated by reconstructing the printed part using computerized tomography (CT) and aligning it with the original design. The results reveal a close correlation between the predicted and the observed distortion, with the thickness of features and the location of support structures having a significant impact on postprint parts. Additionally, the study on build orientation helps understand the distribution of residual stresses and their redistribution after removing support structures.