ArticleProgress in additive manufacturing2026
Residual Stress Relaxation After Aging Heat Treatment in Laser Powder Bed Fusion CM247LC Superalloy Parts Quantified by Neutron-Diffraction-Validated Full-Field Eigenstrain Tomography.
Article in Progress in additive manufacturing, 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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Abstract
Residual stresses generated during laser powder bed fusion (LPBF) can compromise dimensional stability and in-service performance of nickel-based superalloy components, while the quantitative assessment of stress relaxation during post-build heat treatment remains challenging in three dimensions. This paper quantifies the effects of an aging treatment at 900 °C for 8 h on the residual stress and eigenstrain distributions in an LPBF-fabricated CM247LC component. Eigenstrain tomography is used to reconstruct full-field three-dimensional distributions of eigenstrain, residual elastic strain, and residual stress tensors from synchrotron X-ray diffraction measurements of a single residual elastic strain component acquired from only two orthogonal projections. Reconstruction accuracy is independently validated using neutron diffraction strain measurements. The results show substantial residual-stress relaxation after aging, including a marked reduction in the magnitude of all residual stress tensor components across the volume. Statistical analysis of the raw diffraction data demonstrates a pronounced homogenisation of internal macroscopic strains, accompanied by a corresponding decrease in reconstructed eigenstrain components toward near-zero values. Leveraging a highly streamlined two-projection tomographic protocol, these findings quantitatively reveal the three-dimensional mechanics of macroscopic (Type I) stress relaxation without the need for exhaustive experimental beamtime. The results provide critical volumetric data linking thermal exposure to the elimination of distortion-driving eigenstrain gradients. Ultimately, this work represents a significant advancement in additive manufacturing process evaluation, establishing this efficient tomographic framework as a practical, non-destructive tool for optimizing post-build heat treatments and ensuring dimensional stability in complex additively manufactured superalloys. Graphical abstract:
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