Abstract.As an emerging Additive Manufacturing (AM) technique, Selective Laser Melting (SLM) has found a promising application in biomedical field due to its advantages in fabricating Ti-6Al-4V components with specific and customised geometries. It has been reported that accumulated residual stress as a result of the high heating and cooling rates during SLM and the topological design of the components can largely influence the mechanical and functional properties of the fabricated components. In this study three notched samples were produced by SLM manufacturing. The samples were built using the same laser melting conditions on the same base size. The notches ranged in angle from 60° to 120°. Residual stresses in the three notched samples were analysed using the state-of-the-art neutron residual strain measurement instrument, Kowari, at the Australian Nuclear Science and Technology Organisation. A combination of gauge volumes were utilised to obtain high precision measurements at the notch tips and general measurements around the tips. This paper reports on the manufacture and measurement of differing residual stresses in the three SLM fabricated notches. IntroductionAs an emerging Additive Manufacturing (AM) technique, Selective Laser Melting (SLM) has found promising applications in a wide spectrum of industries, e.g. aircraft, automotive and biomedical sectors, due to its advantages in fabricating metal components with specific and customised geometries [1]. The process of SLM manufacture is highlighted in Fig 1. Initially an CAD model of the part to be generated is created (a), the model is then segmented into 50µm slices (b). The slice information is then fed to the SLM machine which melts the required pattern into a bed of powder (c). Once the pass is completed the bed is lowered by 50µm and a new layer of powder added (d) and the next melting pass conducted. Finally the completed part is removed from the powder bed (e) and the unused powder is recycled.An important feature of SLM is that through optimisation of the fabrication parameters (e.g. laser energy, scanning speed, hatch spacing, etc.) and topological design of the components, these SLM fabricated metal components with desired mechanical and functional properties (e.g. ductility, elastic modulus, strength etc.) can be achieved [2]. It is reported that the accumulated residual stress as a result of the high heating and cooling rates during SLM and the topological design of the components can have a significant effect on the mechanical and functional properties of the fabricated components [3][4][5]. This leads us to deduce that understanding and tailoring the residual stress in SLM components is essential. As part of this understanding the effects of topological features, for a given fabrication method, on the residual stress within a component must be examined. Therefore, to investigate the effects of topography on the residual stress in SLM components, a state-of-art neutron
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