| Abstract Scope |
As metal additive manufacturing (AM) is rapidly adopted across industry—driven by advantages over traditional subtractive processes—there is growing interest in controlling residual stresses and distortion to enable downstream manufacturing and assembly and to support qualification and certification of safety‑critical components. This talk highlights the shared physical phenomena in welding and metal AM that govern residual stress and distortion, using a lower‑order residual‑stress modeling framework. In this sense, metal AM can be viewed as a sequential “all‑weld‑metal deposition” process, allowing much of the hard‑won knowledge from welding (e.g., length‑scale effects) to transfer directly—particularly proven mitigation strategies. Key differences relative to welding will also be discussed, along with their implications for control. Examples from a range of AM builds (e.g., PBF vs. WAAM) will be used to connect underlying mechanisms to practical approaches for managing residual stress and distortion. |