Abstract

Cracking is a significant challenge in components fabricated by powder bed fusion using a laser beam (PBF-LB), occurring due to thermal stresses during or after the printing process. This study investigates crack behavior in two geometries–dog bone and cruciform–fabricated with Inconel 738 (IN738) alloy. Finite element analysis for coupled thermomechanical simulations was used to identify stress concentration locations and predict crack formation based on stress intensity factors. The results showed that stress intensity factors at critical locations exceeded the fracture toughness of IN738, indicating a high likelihood of crack formation. Furthermore, the study examined how post-process sequences, including heat treatment (HT) and base plate removal, influence stress distribution and geometric accuracy. Despite geometric differences, both geometries exhibited similar stress patterns and crack behavior, providing valuable insights into designing geometries to mitigate cracking and highlighting the importance of process sequencing in optimizing additive manufacturing.