Residual stress (RS) is the most challenging problem in metal additive manufacturing (AM)
since the build-up of high tensile RS may influence the fatigue life, corrosion resistance,
crack initiation, and failure of the additively manufactured components. While tensile RS is
inherent in all the AM processes, fast and accurate prediction of the stress state within the
part is extremely valuable and results in optimization of the process parameters to achieve a
desired RS and control of the build process. This paper proposes a physics-based analytical …

Rapid and accurate prediction of residual stress in metal additive manufacturing processes
is of great importance to guarantee the quality of the fabricated part to be used in a mission-
critical application in the aerospace, automotive, and medical industries. Experimentations
and numerical modeling of residual stress however are valuable but expensive and time-
consuming. Thus, a fully coupled thermomechanical analytical model is proposed to predict
residual stress of the additively manufactured parts rapidly and accurately. A moving point …