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The laser powder bed fusion (LPBF) process involves using a laser beam to selectively melt metal powder with a desired shape on a substrate to create a part layer-by-layer. As an Additive Manufacturing (AM) process, laser powder bed fusion (commonly referred to as selective laser melting-SLM) offers superior design freedom over conventional manufacturing methods and enables the production of complex, lightweight geometries with applications in the aerospace, automotive, and biomedical industries. In addition to enhanced design freedom, AM technologies provide improved material utilization and allow for reduced assembly needs. However, the reliability and repeatability of additively manufactured parts is a challenge to the wide-scale adoption of the technology for safety critical parts. A critical limitation of process optimization is the prediction and control of residual stresses, distortion, and microstructure evolution. This work focuses on the development and implementation of a numerical modeling technique for the prediction of residual strains within an Inconel 625 LPBF part. The model, using the SIMULIA Additive Manufacturing Scenario App, based on the Abaqus 2018 finite element solver, was developed and analyzed as part of a submission for the NIST AM Benchmark 2018. A sequentially coupled thermo-mechanical analysis was adopted to replicate the building conditions of a single cantilever beam built at the NIST laboratories. The results of the blind study were compared to X-ray diffraction (XRD) measurements of the physical build. The predicted three-dimensional residual strain field showed a high level of accuracy and the submission described in this paper received joint first prize in the residual elastic strain category of the NIST AM Benchmark 2018. The results presented in this paper reflect only findings before the benchmark measurements were posted on the NIST website.

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