Residual Stress Characteristics in Additive/Subtractive Hybrid Manufacturing: A Review

This review methodically expounds on the genesis, distribution characteristics, and control methodologies of residual stress (RS) in additive/subtractive hybrid manufacturing (A/SHM). RS, originating from non-uniform temperature fields during manufacturing, rapid solidification of the molten pool, and complex thermal cycling, are key factors causing component deformation, performance degradation, and even cracking. It is evident that significant limitations are imposed on the industrial implementation of A/SHM technology in the domain of high-end equipment manufacturing. This review methodically unveils the influence patterns of process conditions, such as scanning strategies and laser parameters, on RS distribution. It elucidates the intrinsic relationship between microstructural evolution and RS and summarizes effective approaches to regulating RS through process optimization, post-heat treatment, and material modification. This paper proactively proposes a development direction for precise RS regulation through intelligent monitoring and control. This approach provides a theoretical foundation and technical support to enhance the reliability of A/SHM components and advance their industrial applications.