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

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Review Open Access

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

Shuaiyuan Yan 1,2 Yuying Yang 1,2,* Shuoshuo Qu 3,4,* Yongqian Yang 1,2 Zhaoqiang Chen 1,2 Yang Wu 1,2 Antong Ouyang 1,2 Chonghai Xu 1,2 Guoqing Wang 5 Chuanjia Qi 5 Bin Sun 5 Jianghan Guo 5 Teng Gao 6 Xiaoming Wang 6

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1
School of Mechanical Engineering, Shandong Key Laboratory of CNC Machine Tool Functional Components, Qilu University of Technology (Shandong Academy of Sciences), Jinan 250353, China
2
Shandong Institute of Mechanical Design and Research, Jinan 250031, China
3
Center for Advanced Jet Engineering Technologies (CaJET), School of Mechanical Engineering, Shandong University, Jinan 250100, China
4
Key Laboratory of High-Effciency and Clean Mechanical Manufacture at Shandong University, Ministry of Education, Jinan 250100, China
5
Hisense Refrigerator Co., Ltd., Foshan 528303, China
6
Key Laboratory of Industrial Fluid Energy Conservation and Pollution Control (Ministry of Education), Qingdao University of Technology, Qingdao 266520, China
*
Authors to whom correspondence should be addressed.

Received: 02 May 2026 Revised: 03 June 2026 Accepted: 22 June 2026 Published: 01 July 2026

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© 2026 The authors. This is an open access article under the Creative Commons Attribution 4.0 International License (https://creativecommons.org/licenses/by/4.0/).

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Intell. Sustain. Manuf. 2026, 3(2), 10016; DOI: 10.70322/ism.2026.10016
ABSTRACT: 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.
Keywords: Additive/subtractive hybrid manufacturing; Mechanism of residual stress formation; Residual stress characteristics; Microstructure
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