Investigating Deformation and Residual Stress in Overhang Structures Produced by Laser Powder Bed Fusion: An Experimental And Thermo-Mechanical Simulation Study
DOI:
https://doi.org/10.23055/ijietap.2026.33.5.11197Abstract
In laser powder bed fusion (L-PBF), overhang structures are particularly vulnerable to warping and residual stress buildup due to inadequate thermal dissipation and limited mechanical support. While contour scanning is commonly used to improve surface quality, its effects on stress distribution and deformation mechanisms in overhang geometries are not fully understood. This study systematically investigates the impact of contour scanning on overhang components with angles from 45° to 60°, combining experimental tests with coupled thermo-mechanical finite element (FE) simulations. Overhang specimens made of 316L stainless steel were produced using an SLM 125HL system. Experimental results revealed that increasing the overhang angle led to greater deformation, surface defects, and melt-through occurrences. To better understand these behaviors, an FE model incorporating Goldak’s double-ellipsoidal heat source and temperature-dependent material properties was developed to simulate the evolution of temperature and stress during contour scanning. Using a reduced-geometry approach—where the model is scaled down in all dimensions to represent three deposited layers (90 μm) over a 1 mm scan length, with volume hatching excluded—the simulation successfully replicates the qualitative deformation patterns and residual stress accumulation observed in the experiments. The simulation further reveals that localized thermal gradients around contour paths induce asymmetric warping at the free ends of overhangs and generate stress concentrations near constrained regions. These insights emphasize the pivotal role of contour scanning in the formation of deformation and residual stresses and provide valuable guidance for optimizing processing parameters to successfully fabricate unsupported overhang features in L-PBF.
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