Residual stresses in additively manufactured details: a review

Additive manufacturing methods are currently being introduced into the aerospace industry. Additive manufacturing enables the creation of complexly configured parts, thereby ensuring high efficiency. However, one of the key challenges facing additive manufacturing is residual stress, which arises during additive manufacturing and is present at all stages. Residual stress, a consequence of thermal heating and cooling of the structure, can have a significant impact on the mechanical and operational properties of manufactured parts. This article examines the causes of residual stress in various additive manufacturing methods. Their impact on the strength characteristics of printed structures and the geometric accuracy of their manufacture is assessed. Methods for reducing residual stress at various stages of additive manufacturing are discussed, including additive part modeling and post-manufacturing processing. A review of existing approaches and methods for modeling and predicting residual stress in additively manufactured structures is provided, which is particularly important for reducing residual stress and increasing strength and reliability in critical aerospace components.