Effect of process optimization on laser additive manufacturing of Inconel 718 alloy based on finite element analysis: Thermal and structural evaluation

•The dynamic simulations of the temperature and stress fields are realized.•Stress distributions at multi-paths and different stress components are studied.•The end ablation and core cracking in cladding layers can be well explained.•Selecting small laser power and large scanning speed can reduce residual stress.•The simulation error is controlled within 21 % by comparing the experiment.