Evaluation of the residual stresses in metallic materials produced by additive manufacturing technology: effect of microstructure

Additive manufacturing (AM) of metals and alloys opens tremendous opportunities in production of parts with complex shapes and geometries. One of the main challenges is formation of residual stress during fabrication processes which substantially affects service life of engineering components. This paper provides a brief introduction to different types, formation mechanisms, and measurement techniques of the residual stress in metals produced by AM technology. The highlight of this study is to propose a novel quantitative model to estimate residual stress in 3D printed metallic components using micromechanical analysis. Finally, the validity of the proposed model is examined by comparison with the experimental data available in literature.