Numerical Simulation and Experimental Study on the Influence of Scanning Strategy on Stress–Strain Behavior of GH3536 in Laser Powder Bed Fusion

High residual stresses significantly impact component performance during laser powder bed fusion (L-PBF) of GH3536 alloy. This study systematically investigates the effects of five scanning strategies (X-Scan, XY-Scan, R67, CB90, CB67) on residual stresses and deformation behavior in laser powder bed fusion-formed GH3536 high-temperature alloy. This is achieved by establishing a thermomechanically coupled mesoscale finite element model and combining it with experimental validation. The model was developed on the ANSYS APDL platform using a sequential coupling algorithm. It comprehensively considered melting latent heat, material nonlinearity, and dead-body element technology. While ensuring computational accuracy, significant computational efficiency gains were achieved through geometric scaling and reasonable simplifications (e.g., neglecting evaporation effects and assuming material isotropy). Results indicate that the 67° interlayer rotational scanning (R67) significantly reduces residual stresses, attributed to the breaking of thermal accumulation symmetry by asymmetric scanning. Component deformation is primarily governed by thermal stresses, with simulation results showing less than 10% deviation from experimental measurements. Despite the model’s medium-to-small scale and omission of size effects, its predicted trends highly correlate with X-ray diffraction measurements, validating its reliability for scan strategy optimization. Electron backscatter diffraction (EBSD) analysis further examined grain size and orientation differences at the microstructural level under the R67 strategy, revealing a more refined grain structure and KAM values. This provides theoretical support for L-PBF forming of nickel-based high-temperature alloys.