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<p>Laser powder bed fusion (LPBF) enables near-net-shape manufacturing of complex metal components with exceptional geometric freedom. However, the rapid cyclic heating and cooling inherent to the process generates steep thermal gradients and plastic incompatibility, resulting in the accumulation of high residual stresses within printed components. These residual stresses can drive distortion and cracking, degrade fatigue performance, and reduce dimensional accuracy. Most existing studies attempt to mitigate residual stress using isolated approaches, which complicates their translation into robust manufacturing practice. This review therefore organizes residual stress mitigation into a system-level workflow spanning simulation, process optimization, material-level control, and post-treatment management. Multiscale simulation approaches can be employed to identify the dominant contributors to residual stress, thereby guiding the selection of in-process mitigation strategies and geometry design, including process parameter optimization, scan pattern and sequence design, and structural design. Material-level strategies, such as powder reuse governance, process atmosphere control, transformation engineering, and in situ alloying, are complementary approaches for stabilizing processing conditions and improving the consistency between simulation predictions and practical manufacturing environments. Post-treatment approaches, including stress-relief heat treatment, vibration-based methods, and surface peening techniques, can be further applied to achieve application-oriented residual stress control. These strategies should operate within a closed-loop framework in which experimental measurements are continuously fed back into the model to enable calibration and iterative refinement of process strategies. The integrated workflow proposed in this review provides a practical framework for residual-stress-controlled LPBF manufacturing, facilitating the transition from laboratory-scale optimization toward reliable and repeatable industrial production.</p>

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A workflow for residual stress control in laser powder bed fusion manufacturing

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年7月31日

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  • Shixiang Zhou,
  • Qichen Guo,
  • Mingchuan Li,
  • Qishun Wang,
  • Xin Xu,
  • Shuai Chang,
  • Wentao Yan,
  • Liqun Li,
  • Jun Ding

摘要

Laser powder bed fusion (LPBF) enables near-net-shape manufacturing of complex metal components with exceptional geometric freedom. However, the rapid cyclic heating and cooling inherent to the process generates steep thermal gradients and plastic incompatibility, resulting in the accumulation of high residual stresses within printed components. These residual stresses can drive distortion and cracking, degrade fatigue performance, and reduce dimensional accuracy. Most existing studies attempt to mitigate residual stress using isolated approaches, which complicates their translation into robust manufacturing practice. This review therefore organizes residual stress mitigation into a system-level workflow spanning simulation, process optimization, material-level control, and post-treatment management. Multiscale simulation approaches can be employed to identify the dominant contributors to residual stress, thereby guiding the selection of in-process mitigation strategies and geometry design, including process parameter optimization, scan pattern and sequence design, and structural design. Material-level strategies, such as powder reuse governance, process atmosphere control, transformation engineering, and in situ alloying, are complementary approaches for stabilizing processing conditions and improving the consistency between simulation predictions and practical manufacturing environments. Post-treatment approaches, including stress-relief heat treatment, vibration-based methods, and surface peening techniques, can be further applied to achieve application-oriented residual stress control. These strategies should operate within a closed-loop framework in which experimental measurements are continuously fed back into the model to enable calibration and iterative refinement of process strategies. The integrated workflow proposed in this review provides a practical framework for residual-stress-controlled LPBF manufacturing, facilitating the transition from laboratory-scale optimization toward reliable and repeatable industrial production.