Mechanical Engineering ETDs

Publication Date

Spring 4-12-2018


Thermal cycling and repeated melting/solidification cycles characteristic of 3D metal printing processes causes buildup of residual stress in 3D printed parts. Using laser engineered net shaping (LENS®), residual stresses are formed leading to deformation and possible cracking of the 3D printed metal components. The LENS process offers opportunities for rapid prototyping, alternative manufacturing processes, and repair of worn/broken components so it is important to be able to minimize the effects of residual stress. Work was performed to understand the benefit of substrate heating on reducing residual stress in metal parts made using the LENS process. Substrate deformation, and destructive methods are used to determine residual stress at various levels of bed heating. Components printed at a range of heated bed temperatures will be compared, simulations that demonstrate the effects of the heating will be shown, and results will be discussed.


Metal 3D printing, Additive Manufacturing, Residual Stress, Digital image correlation

Degree Name

Mechanical Engineering

Level of Degree


Department Name

Mechanical Engineering

First Committee Member (Chair)

Yu-Lin Shen

Second Committee Member

Mehran Tehrani

Third Committee Member

David Keicher

Document Type




Included in

Manufacturing Commons