（ 1. Key Laboratory of Metallurgical equipment and its Control, Ministry of Education, Wuhan University of
Science and Technology, Wuhan 430081, China; 2. National Innovation Institute of Digital Design and
Manufacturing, Wuhan 430074, China）
Abstract：The selective laser melting forming technology is increasingly used in the manufacture of complex com‐
ponents for aerospace equipment. However, such parts have thin-walled curved features have a large residual
stress, which could induce large residual stress and deformation and seriously restrict the forming accuracy and
quality. AlSi10Mg is widely used in the production of parts in the field of additive manufacturing due to its low
density, high specific strength and good corrosion resistance. In this paper, we analyze the influence of the process
parameters and geometric features on the support connection by simulating the laser-selective melting of thinwalled surface features under non-solid support, and study the residual stress distribution and deformation law of
the surface features under non-solid support based on this simulation. The thermoplastic method is used to simulate
the connection of the non-solid support with different support forming laser power and support structure, and the
support parameters are selected with the goal of connection effect. The residual stress and deformation distribution
of thin-walled surface features with different wall thicknesses and forming heights are simulated, experimentally verified and discussed based on the intrinsic strain model with the application of the selected support parameters.
The simulation results show that the strength of the non-solid support connection is related to the laser power. The
decrease of the laser power leads to the decrease of the stress level at the support connection. The stress values at
the support connection of each group decrease by14.7%,14.6% and 17.3% respectively with the decrease of the la‐
ser power. When optimizing non-solid support parameters for forming simulation and experiment of thin-walled
curved parts, it is found that the peak deformation of thin-walled curved parts increase with the rise of forming
height, and the thinner the wall thickness of the parts, the greater the peak deformation. Under the condition of
using laser power of 350 W, 3×3 grids and adding independent external contour support, the non-solid support con‐
nection effect of AlSi10Mg is the best, and with the increase of laser power, the support connection is also stronger.
The addition of non-entity contour support can effectively improve the support connection. The local deformation
of thin-walled curved parts with non-solid support is obviously improved. The residual stress distribution of thinwalled curved parts is mainly affected by the Z-direction normal stress of the parts, and increases with the increase
of the thickness of the parts.
2024, Vol. 34 
