Effective Prediction of Residual Stress and Deformation in Titanium Alloy Hip Joints by Laser Powder Bed Fusion

ZHAO Weihong; WANG Bingyu; LI Haoqing

doi:10.3969/j.issn.1674-6457.2025.09.009

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Journal of Netshape Forming Engineering ›› 2025, Vol. 17 ›› Issue (9) : 95-102. DOI: 10.3969/j.issn.1674-6457.2025.09.009

Light Alloy Forming

Effective Prediction of Residual Stress and Deformation in Titanium Alloy Hip Joints by Laser Powder Bed Fusion

ZHAO Weihong^1,*, WANG Bingyu¹, LI Haoqing²

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Abstract

The work aims to enhance prediction accuracy and reliability so as to address the inaccuracy in predicting residual stresses and deformations during the manufacture of large-scale and geometrically complex components (such as titanium alloy hip joints) using Laser Powder Bed Fusion (LPBF) technology. In this study, a scheme for establishing a set of laser scanning vectors was proposed, which sequentially activated each vector set in a preset order to more precisely approximate the actual laser scanning process. This method comprehensively considered the impact of laser scanning strategies on residual stresses and deformations, thereby improving prediction accuracy for large-scale components. The simulation scheme considering scanning strategies (employing the laser scanning vector set) exhibited an error below 10%, while the model ignoring scanning strategies had an error as high as 27%. This result suggested that considering scanning strategies by establishing a laser scanning vector set significantly improved the prediction accuracy of residual stresses and deformations in titanium alloy hip joints manufactured by LPBF. The proposed scheme for establishing a laser scanning vector set has achieved notable success in solving the prediction challenges of residual stresses and deformations in large-scale components prepared by LPBF. This method not only enhances prediction accuracy but also provides strong support for the widespread application of LPBF technology in the production of customized metal orthopedic implants.

Key words

laser powder bed fusion / titanium alloy hip joints / residual stress / deformation / thermal-mechanical coupling analysis

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ZHAO Weihong, WANG Bingyu, LI Haoqing. Effective Prediction of Residual Stress and Deformation in Titanium Alloy Hip Joints by Laser Powder Bed Fusion[J]. Journal of Netshape Forming Engineering. 2025, 17(9): 95-102 https://doi.org/10.3969/j.issn.1674-6457.2025.09.009

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