The processing of Ni 50 Ti 50 (at.%) alloy via powder bed fusion using a laser beam (PBF-LB) technique has been reported to significantly alter the atomic percentage of Ni in the final NiTi part when compared to the feedstock composition, and the ensuing variations in the phase characteristics and transformation temperatures. Residual stresses are also another challenge in the PBF-LB processing of NiTi. These PBF-LB challenges stem from the choice of laser scanning strategy, and process parameter selection typically defined by volumetric energy density (VED). Heat treatment also plays a crucial role in releasing residual stresses and effectively adjusting or tuning the final properties of as-built NiTi components.

Due to the unique characteristics of nitinol (NiTi) such as shape memory and super-elasticity, it is widely utilized in various industries, particularly in aerospace and biomedical applications. Additive manufacturing technology can provide the accurate dimensioning of NiTi components, even for those with intricate and complex geometries. However, the presence of residual stresses poses a significant concern from additive manufacturing. These residual stresses can adversely impact the structural integrity and performance of the manufactured parts, necessitating careful consideration and management. This study delves into a distinctive approach for predicting residual stresses within additive manufactured NiTi components, employing a simple, non-destructive, and cost-efficient method that integrates beam mechanics equations with finite element analysis (FEA). This work aimed to develop a rapid and accurate method for measuring the residual stress from additively manufactured nitinol beams which will be validated via established techniques such as hole-drilling, XRD and/or neutron diffraction.