Progress in machining-induced residual stress and microstructural evolution of inhomogeneous materials and composites

The inhomogeneous materials and composites with a high strength-to-weight ratio, high dimensional stability, and versatile design options are recognized as the potential next-generation and functional materials to replace the traditional ones. The advanced composites as major components have been deployed in the engineering fields of aerospace, automotive transportation, energy production involving the wind and nuclear power plants, and oil and gas productions. The presence of residual stress generated within the inhomogeneous materials and composites during manufacturing process has been recognized in engineering design practice. The machining-induced uncontrolled and undesirable residual stress in conjunction with morphological evolution of inhomogeneous structures at the microscale may significantly influence the mechanical performances and structural integrity of engineering composites. In this review, recent progresses of theoretical and experimental solutions for evaluating the residual stress distributions, the interacting effects of multiple reinforced microphases, effective properties, and homogenization of inhomogeneous composites are discussed. The analyses of thermal effect due to metallurgical processes and additively manufacturing are provided to elucidate the typical conditions, deformations, and fatigue behaviors in fiber-reinforced, metal-based, and ceramic composite materials, as well as the thin film and coating composites. In addition, this paper also reviews the quantitative evaluation of controlling mechanisms of residual stress and microstructural evolution in functional composites and provides future perspectives on the potential applications of inhomogeneous materials and composites for further development.