A coupled Computational Fluid Dynamic (CFD)-Finite Element Method (FEM) model is developed for studying the heat and thermal stress distribution in EBM®. The coupled CFD-FEM model combines the ability of CFD in considering the effects of fluid convection, with the ability of FEM in calculating the thermal stress. Three different electron beam scanning speeds are used to fuse the Ti-6Al-4V. According to the numerical results, the negative temperature coefficient of surface tension is responsible for the formation of an outward flow in the molten pool on the top surface during the EBM® of Ti-6Al-4V. Also, the influence of electron beam scanning speed on the thermal stresses developed in the domain is studied. Heat input and cooling rate are the dominant factors influencing the level of thermal stresses developed during melting and cooling steps, respectively. Therefore, the minimum electron beam scanning speed of 100 mm/s resulted in the maximum and minimum thermal stresses during melting and cooling steps, respectively.