Multilayer direct laser metal deposition is a fabrication process in which the parts are fabricated
by creating a molten pool into which particles are injected. During fabrication, a complex
thermal history is experienced in different regions of the build, depending on the process
parameters and part geometry. The thermal history induces residual stress accumulation in the
buildup, which is the main cause of cracking during the fabrication. The management of residual
stress and the resulting distortion is a critical factor for the success of the process. A thermostructural finite element model (FEM) of the process is developed, and the analysis reveals
different patterns of residual stress in the thin-walled structures depending on the deposition
strategy and the geometry of the structures. The residual stress patterns obtained from finite
element analysis (FEA) are in good agreement with the experimental results.Mechanical Engineerin
