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Determination of thermal stress distribution in metallic layer during selective laser sintering using finite element method

Selective Laser Sintering (SLS) is used to make strong and hard metallic functional components layer by layer directly from several kinds of metallic powders. The high laser power (about 1 kW) during SLS results in high-localised temperature rise (about 1000â€“1500Â°C). Thermal stresses are generated due to temperature gradient. The study of thermal stress distribution within the metallic layer is important from the quality of the product point of view. A transient Finite Element Method (FEM)-based 2D temperature and thermal stress model has been developed to calculate the temperature distribution and thermal stress distribution within a single metallic layer formed on the powder bed using SLS. This paper predominantly deals with the effects of laser power and time of scanning on thermal stress distribution within a single layer of Ni-based alloy (82.8 %Ni, 9.5 %Cr, 2%B, 3%Si, 2.3%Fe, 0.4%C) during SLS.