A critical review on residual stress in laser additive manufacturing：formation mechanism，characterization and control method

Abstract

Laser additive manufacturing （LAM） enables the integrated direct formation of high-performance metallic components with complex geometry. However， the non-uniform distribution of temperature gradients， in-situ heat treatment effects， non-equilibrium solid phase transformations， and heterogeneous microstructure during the process result in intricate residual stresses that significantly affect the quality and overall performance. A comprehensive review of residual stress in LAM by introducing its fundamental definition and classification is provided in this paper. Furthermore， the particularity， formation mechanisms， characterization methods， and regulation techniques associated with residual stress in LAM is systematically reviewed. The subsequent sections introduce various characterization methods for residual stress in LAM components， along with their respective characteristics. Additionally， the applicability， advantages， and disadvantages of each method are presented. Furthermore， the methods for controlling residual stress can be categorized into post-treatment control and in-situ treatment control. Finally， the joint effect of different types of residual stress should be considered in the study of the cause and evolution mechanism of residual stress in LAM. The characterization method of residual stress should be integrated with various methods to facilitate mutual verification. To mitigate the impact of stress concentration on the printing process and resultant quality， as well as minimize the influence of post-processing stress on part accuracy， it is imperative to investigate in-situ control methods for residual stress and explore real-time online monitoring techniques for LAM.

Keywords

• laser additive manufacturing
• residual stress
• residual stress characterization
• finite element simulation
• residual stress control