Residual stress distribution in an additively manufactured complex structure by neutron diffraction measurement

Ke An; Yan Chen; Matt Frost

doi:10.1016/j.matlet.2025.139877

Residual stress distribution in an additively manufactured complex structure by neutron diffraction measurement

Research output: Contribution to journal › Article › peer-review

Abstract

Residual stress in an aerodynamically shaped Ni-based superalloy airfoil fabricated by laser powder bed fusion was measured by neutron diffraction. The experiment was conducted by considering the complex shape, implementing computer aided experiment planning, and automatic alignment at each rapid measurement. The 3-dimensional (3D) residual stress distribution in the airfoil is presented in this work, which lacks symmetry due to the complex geometry of the airfoil. The results provide theoretical thermal processing models a complete residual stress dataset of simulation validation on 3D shape complex structure.

Original language	English
Article number	139877
Journal	Materials Letters
Volume	406
DOIs	https://doi.org/10.1016/j.matlet.2025.139877
State	Published - Mar 1 2026

Funding

The research was performed at the Spallation Neutron Source (IPTS-16063, 19577), a DOE Office of Science User Facility operated by the Oak Ridge National Laboratory. The authors thank Dr. Yan Gao from GE Global Research Center for providing the sample.

Keywords

Additive manufacturing
Complex shape
Neutron diffraction
Residual stress

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10.1016/j.matlet.2025.139877

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title = "Residual stress distribution in an additively manufactured complex structure by neutron diffraction measurement",

abstract = "Residual stress in an aerodynamically shaped Ni-based superalloy airfoil fabricated by laser powder bed fusion was measured by neutron diffraction. The experiment was conducted by considering the complex shape, implementing computer aided experiment planning, and automatic alignment at each rapid measurement. The 3-dimensional (3D) residual stress distribution in the airfoil is presented in this work, which lacks symmetry due to the complex geometry of the airfoil. The results provide theoretical thermal processing models a complete residual stress dataset of simulation validation on 3D shape complex structure.",

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AU - Chen, Yan

AU - Frost, Matt

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N2 - Residual stress in an aerodynamically shaped Ni-based superalloy airfoil fabricated by laser powder bed fusion was measured by neutron diffraction. The experiment was conducted by considering the complex shape, implementing computer aided experiment planning, and automatic alignment at each rapid measurement. The 3-dimensional (3D) residual stress distribution in the airfoil is presented in this work, which lacks symmetry due to the complex geometry of the airfoil. The results provide theoretical thermal processing models a complete residual stress dataset of simulation validation on 3D shape complex structure.

AB - Residual stress in an aerodynamically shaped Ni-based superalloy airfoil fabricated by laser powder bed fusion was measured by neutron diffraction. The experiment was conducted by considering the complex shape, implementing computer aided experiment planning, and automatic alignment at each rapid measurement. The 3-dimensional (3D) residual stress distribution in the airfoil is presented in this work, which lacks symmetry due to the complex geometry of the airfoil. The results provide theoretical thermal processing models a complete residual stress dataset of simulation validation on 3D shape complex structure.

KW - Additive manufacturing

KW - Complex shape

KW - Neutron diffraction

KW - Residual stress

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VL - 406

JO - Materials Letters

JF - Materials Letters

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ER -

Residual stress distribution in an additively manufactured complex structure by neutron diffraction measurement

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