Abstract:
Selective laser melting (SLM) enables the rapid fabrication of complex metallic components. However, significant thermal gradients and heterogeneous microstructural evolution are tend to be generated by the localized rapid melting and solidification processes involved in SLM, thereby introducing high residual stresses within the components. The scanning strategy, as a key process parameter, is recognized to play a critical role in regulating heat input and thermal field distribution, thus influencing the formation and release of residual stresses. The research focused on SLM 316L stainless steel, studying the influence patterns of three scanning strategies, namely bidirectional linear, stripe, and checkerboard, on the residual stress field. The regulatory mechanisms of scanning paths on thermal accumulation, solidification behavior, grain orientation, and melt pool boundary evolution are elucidated. The results show that residual stresses are relatively high under bidirectional linear scanning, with a maximum peak of 123 MPa. In comparison, stripe scanning reduces the peak residual stress by approximately 63% (with a maximum peak of 45.5 MPa), while chessboard scanning reduces it by about 84% (with a maximum peak of 19.6 MPa). Both strategies significantly improve stress distribution uniformity. The coupling mechanisms among scanning strategy, thermal field, microstructure, and residual stress are thoroughly examined in this study, with theoretical support and process guidance provided for optimizing residual stress and enhancing the reliability of SLM-fabricated 316L components.