Additively manufactured (AM) metallic materials commonly possess substantial microscale
internal stresses that manifest as intergranular and intragranular residual stresses. However,
the impact of these residual stresses on the mechanical behaviour of AM materials remains
unexplored. Here we combine in situ synchrotron X-ray diffraction experiments and
computational modelling to quantify the lattice strains in different families of grains with
specific orientations and associated intergranular residual stresses in an AM 316L stainless …

Metal additive manufacturing (AM) has attracted much attention in recent years due to its
ability of producing parts with complex geometry. Unfortunately, the large temperature
gradient during fabrication leads to residual stresses which undesirably result in distortion
and even crack of as-built parts. A computational framework is used to study how residual
stresses form and evolve in AM parts at the length scale of individual grains, including a
multi-physics thermal-fluid flow model, a phase field model for grain growth and a crystal …