Anisotropic Residual Stress Measurements In Additively Manufactured 316 Stainless Steel Parts

Additive manufacturing (AM) using laser powder bed fusion (L-PBF) is increasingly used to produce complex parts for industries like aerospace and medical devices. The intrinsic characteristics of AM – layer-wise deposition and rapid thermal cycling – generate significant, anisotropic, residual stresses that can compromise part quality and performance. Recent studies highlight how these stresses are strongly influenced by process parameters and build orientation. X-ray diffraction (XRD) techniques, including sin²ψ and advanced two-dimensional approaches, have become the preferred methods for non-destructive, directionally resolved measurement of residual stress in AM metals. This review surveys advancements in XRD residual stress methods with a focus on the analysis of additively manufactured 316L stainless steel that has been post-treated by shot peening. Coordinated development of AM and shot peening underscores the importance of residual stress characterization to guide process optimization and improve the structural integrity of AM components across diverse industrial sectors.