Evaluating residual stress in additively manufactured nitinol shape memory alloy.

This study provides a comprehensive analysis of residual stress characteristics in nitinol parts fabricated via laser powder bed fusion (PBF-LB). Unlike previous works that primarily focus on qualitative assessments or single-measurement techniques, this research employs a multi-modal experimental approach, Electronic Speckle Pattern Interferometry-Hole Drilling (ESPI-HD) and X-ray Diffraction (XRD), to achieve a more precise and spatially resolved evaluation of residual stress distribution. Furthermore, the study establishes a direct correlation between residual stress evolution and in situ pyrometric melt pool temperature data, an aspect that has not been extensively explored in prior investigations. A key novel finding is the non-monotonic relationship between volumetric energy density (VED) and residual stress. In this work, laser power was kept constant, and VED was varied by adjusting scanning speed and hatch spacing. The results show that the average residual stress initially increases with decreasing scan speed and hatch spacing, plateaus at a critical threshold, and subsequently decreases. However, residual stress was also found to vary in the build direction, indicating the complex stress distributions and accommodation mechanisms within the material. Additionally, an inverse relationship was recorded between the thermal gradient and VED which challenges conventional assumptions about their relationship. These insights offer a new perspective on optimizing PBF-LB process parameters for enhanced structural performance and long-term reliability of additively manufactured nitinol.