Residual stress has been among the primary problems in the laser powder bed fusion (LPBF) additive manufacturing. Nevertheless, complex physics and multi-scale nature of the problem make an accurate prediction of residual stress at the part level a great challenge. Thus, the present study developed the finite element framework to predict the part scale residual stress development in the LPBF of Inconel 718. Two-scale models were used coherently. A mesoscale model calculated the stress formation in a deposited powder layer by considering the influence of process conditions and scan strategies. Subsequently, the inherent strain approach was used for the part level prediction. The inherent strain values were estimated according to numerical results from the mesoscale model. Numerical validation was made by comparing the transient development of residual stress with reported measurements from the neutron diffraction of over 200 data points. The proposed framework provided the prediction which matched excellently with experimental results. Ultimately, the present study established the proven framework which could be used for further investigation on part scale-related issues in the LPBF process.

残余应力已成为激光粉末床熔合（LPBF）增材制造中的主要问题之一。然而，复杂的物理学和问题的多尺度性质使得准确预测零件级残余应力成为一个巨大的挑战。因此，本研究开发了有限元框架来预测Inconel 718 LPLP中零件尺度的残余应力发展。相干地使用了两尺度模型。中尺度模型通过考虑工艺条件和扫描策略的影响来计算沉积粉末层中的应力形成。随后，固有应变方法用于零件液位预测。根据中尺度模型的数值结果估计固有应变值。通过比较残余应力的瞬态发展与来自200多个数据点的中子衍射报告的测量结果进行了数值验证。所提出的框架提供了与实验结果非常匹配的预测。最终，本研究建立了行之有效的框架，可用于进一步研究LPBF过程中与零件规模相关的问题。