Study on the effect of variable laser power on residual stress distribution in laser directed energy deposition of Ti6Al4V

In the laser directed energy deposition (LDED) process, cyclic thermal stress loading induces significant temperature variations on the surface and subsurface of the workpiece during repeated heating, leading to the formation of residual tensile stress during cooling. This adversely affects the mechanical properties of the parts, causing deformation and defects. In this study, a heat transfer model and a three-dimensional stress model were established based on finite element analysis. A variable laser power (VLP) deposition strategy was proposed to dynamically simulate the temperature and stress fields of Ti6Al4V titanium alloy under different deposition strategies. The model was validated by collecting substrate temperature variations using thermocouples and measuring residual stress with an X-ray diffractometer (XRD). Experimental results showed that the temperature error between the simulation and the experiment ranged from 6.25 % to 10.12 %, with an average stress simulation error of 6.92 %. Among the four strategies, the samples using the VLP strategy showed a reduction in the average substrate temperature by 12.68 % to 15.08 % compared to the other three strategies. The maximum principal stress in the layer was reduced by 7.8 % to 32.14 %, and the residual stress distribution was more uniform in all directions. The microstructure of the deposition layer further indicated that the VLP strategy improves residual stress distribution and leading to better deposition quality.