Residual Stress Evaluation of Metal AM Components
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Residual Stress Evaluation of Metal AM Components


CRP year




Project Reference No.


Technical Lead

Bochuan Liu

AM process & materials used

Laser powder bed fusion (In718)


Laser powder bed fusion AM has a unique thermal cycle that involves a steep thermal gradient up to the materials’ melting point, rapid solidification, and then re-melting on subsequent layers. This causes residual stress to build up in the part which is a significant issue given its effect on distortion, reduced performance and premature failure of the part. This CRP project:

  • Measured the residual stress distribution in AM benchmarking features using electronic speckle pattern interferometry (ESPI) hole-drilling as a comparison to conventional strain gauge hole-drilling
  • Studied the influence on the stress from altering the build parameter strategies
  • Investigated the relationship between stress distribution and distortion on benchmarking features (see Figure 1)
  • Generated a data library for AM process simulation




If you are a member you can access the deliverables of this project here.