This paper compares the predicted distortion of a manifold geometry fabricated by laser powder bed fusion between an established finite element model using solid elements and a newly developed in this paper finite element model using shell elements. The developed finite element models utilized two methods to induce a strain field (inherent strain and analytical thermal methods). The predicted distortions from these models were also compared with experimentally measured distortions. The results showed that the predicted distortion using solid elements is more suitable to predict the buckling effect on the manifold geometry. Despite that, the model using shell elements showed an accurate prediction of distortion in many areas of the manifold, and it proved to be computationally more efficient (2.4 times faster), this model showed lower accuracy in the prediction of distortion generated by buckling. However, shell elements could be used in other applications where the bucking is not the driving mechanism for the prediction of distortion in laser powder bed fusion or in applications where the accuracy of distortion is not a requirement (e.g.,support structures).

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This paper presents numerical analyses of a welding simulation of a bogie frame side beam. The simulation is based on an analytical thermal model coupled with a non-linear structural finite element model using shell elements enabling the welding simulation of large structures. The predicted clamping forces, distortions, and residual stresses for different clamping conditions and plate thicknesses are analysed in terms of manufacture. A new fatigue model based on the endurance limit approach is proposed using residual stresses to predict the S-N curves. The predicted S-N curves with the proposed model showed close correlation with the S-N curves for class F and class F2 welds of the BS7608 standard, demonstrating its validity and potential use in design.