If you are experiencing convergence issues during an AM Process Simulation, try one or more of these suggestions, as appropriate:
If Large Deflection is on, turn it off, under Analysis Settings for the static structural analysis. Large deflection is off by default for AM Process Simulations but it is useful in some cases and users often turn it on.
For thin-walled parts, the walls can tend to take on a buckled or dimpled shape as the build progresses. In these cases, large deflection is required and convergence difficulties may be seen. If that is the case, you will need an adequate mesh to capture this deformation. Consider using a finer mesh or switch to a quadratic (midside-noded) element (Element Order in Mesh Details). See Capturing a Buckled Shape with Large Deflection for details.
Switch to the Direct Solver for Solver Type under Analysis Settings for the static structural analysis.
If you are using customized materials, be sure you have defined a nominal strength at the melt temperature, as a near zero modulus and/or yield strength could lead to convergence problems. (Ansys predefined materials take care of this internally.)
If you are using a Layered Tetrahedrons mesh with a geometry imported from an .stl file, be sure the faceted geometry is cleaned up as much as possible. (See Cleanup of Facets). Depending on the quality of the .stl file, you may see convergence issues because of poor tet elements created with a "dirty" .stl file.
If you are using creep properties in a heat treatment analysis and you experience convergence issues in the transient thermal solution, increase the sub-steps in the Transient Thermal module in order to avoid an abrupt change in temperature.