Residual Stress Characterization of an Additively Manufactured Titanium Alloy

Additive manufacturing (AM) has emerged as a revolutionary technology for producing complex and customized components, particularly in aerospace and medical industries, using materials like titanium alloys known for their exceptional strength-to-weight ratio. However, the inherent thermal gradients and rapid solidification processes during AM can introduce residual stresses in the manufactured parts, significantly affecting their mechanical properties and structural integrity. This study focuses on the comprehensive characterization of residual stresses in additively manufactured titanium alloy components, particularly on understanding the influence of various AM process parameters, post-processing techniques, and part geometries. We employ state-of-the-art semi-destructive techniques, incremental hole drilling and strain gauging to map and quantify the residual stress distribution within the fabricated parts. We elucidate the factors contributing to residual stress formation through carefully designed experiments and numerical simulations, including thermal history, cooling rates, and build orientation. The findings of this research not only advance our fundamental understanding of residual stress mechanisms in additively manufactured titanium alloys but also provide valuable insights for optimizing the AM process and post-processing steps to minimize residual stress-induced defects and enhance the reliability of components in critical applications. Ultimately, this work contributes to the broader goal of unlocking the full potential of additive manufacturing for high-performance engineering materials like titanium alloys.