"Residual Stress in Laser Powder Bed Fusion of 316L Stainless Steel: Origins and Characterization" 

Rajeshree Varma, MSE PhD Candidate 

Advisors: Prof. Paul Mort, Prof. Mike Titus

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ABSTRACT

Residual stresses (RS) are intrinsic to laser powder bed fusion (LPBF) due to steep thermal gradients, rapid solidification, and repeated layer-by-layer deposition. In 316L stainless steel, these stresses are often anisotropic and can approach the material’s yield strength, driving distortion, cracking, and challenges in part qualification. This document critically reviews the current understanding of RS in LPBF, focusing on their origins, methods of characterization, and approaches for mitigation, such as thermal treatments and mechanical surface modifications. By connecting mechanisms of stress generation with advances in measurement and control, the review identifies gaps in linking local stress states with processing conditions and highlights opportunities for systematic frameworks that unify experimental and computational approaches.