Impact of pore defects on laser additive manufacturing of Inconel 718 alloy based on a novel finite element model: Thermal and stress evaluation

•A 3D pore distribution model is constructed based on the experimental results.•The simulations of temperature and stress fields considering pores are realized.•The residual stress at the defects increases with the maximum increase of 14.87%.•The phenomenon of cracking inside the cladding layer can be further explained.•The average simulation error of the novel model can be controlled within 12%.