Residual Stress Analysis in Additive Manufacturing

Residual stresses are self‐equilibrating internal forces that remain in a component after the removal of the external loading or thermal source that created them. In additive manufacturing (AM), rapid and localised heating and cooling generate steep thermal gradients and phase transformations, leading to complex patterns of tensile and compressive residual stress. These stresses can distort parts, impair dimensional accuracy and reduce fatigue life or fracture resistance. Analysis of residual stress in AM combines high‐resolution measurement methods with advanced multi‐physics simulation to predict stress‐induced distortion and guide process optimisation. Research spans in situ diffraction techniques, computational fluid‐structure coupling and fracture mechanics, offering pathways to tailor build strategies, scanning patterns and post-processing treatments. A clearer understanding of stress evolution in metal AM underpins efforts to enhance component reliability in aerospace, biomedical and automotive applications.

Research from Nature Portfolio

Operando neutron diffraction has been used to monitor lattice strain and phase boundary motion in real time during the layer-by-layer fabrication of low-temperature transformation steel. This approach reveals how elastic and plastic strain distributions evolve under the interplay of face-centred cubic and body-centred cubic transformations, enabling the design of targeted residual stress states for improved fatigue performance and stress-corrosion resistance. In a complementary study on nickel-based superalloy IN718, X-ray diffraction and high-resolution electron backscatter diffraction were combined to map misorientation and stress relief in as-built components. The findings demonstrate that grain morphology and scanning strategy critically influence residual stress profiles and suggest microstructure-guided approaches to stress mitigation.

Residual Stress Analysis in Additive Manufacturing publication trend

The graph below shows the total number of articles in residual stress analysis in additive manufacturing across all publications each year (not limited to Nature Index journals).

Technical terms

Residual stress: Internal stresses locked into a material after manufacturing or processing, independent of external loads.

Additive manufacturing: Layer-by-layer fabrication of components directly from digital models, often known as 3D printing.

Neutron diffraction: A non-destructive technique using neutron scattering to measure internal lattice strains and infer residual stress.

Finite element modelling: Numerical method that divides a structure into discrete elements to simulate mechanical, thermal or coupled phenomena.

J-integral: A contour integral in fracture mechanics representing the energy release rate around a crack tip and predicting crack growth tendencies.

References

1. Operando neutron diffraction reveals mechanisms for controlled strain evolution in 3D printing. Nature Communications (2023).
2. The residual stress in as-built Laser Powder Bed Fusion IN718 alloy as a consequence of the scanning strategy induced microstructure. Scientific Reports (2020).
3. Fabrication sequence optimization for minimizing distortion in multi-axis additive manufacturing. Computer Methods in Applied Mechanics and Engineering (2023).
4. Cracking prediction at solid-tooth support interface during laser powder bed fusion additive manufacturing. Journal of Science Advanced Materials and Devices (2023).
5. Residual stresses in additively manufactured AlSi10Mg: Raman spectroscopy and X-ray diffraction analysis. Materials & Design (2021).