The Effects of Overhang Forming Direction on Thermal Behaviors during Additive Manufacturing Ti-6Al-4V Alloy

Selective laser melting was recently introduced to fabricate complex parts that are likely to contain overhangs. Process parameters, scanning strategies, support structures, and fast prediction techniques are being frequently studied, but little information about overhang forming direction has been reported. In this study, the effects of overhang forming direction in the working plane on temperature evolution and distortion processes during selective laser melting of Ti-6Al-4V alloy were examined by means of numerical simulation and experimental verification. We found that forming from different directions can lead to significant differences in the early stage of the overhang building process, which were verified by both the simulations and the experiment. Some analyses were performed when enough layers had been built and suggestions are also given.