A Review of Residual Stress and Deformation in Metal Additive Manufacturing: Formation Mechanisms, Influencing Factors, Prediction Methods, and Mitigation Strategies

Metal additive manufacturing (MAM) enables the fabrication of geometrically complex and high-performance components but is accompanied by steep thermal gradients, repeated thermal cycling, phase transformation, residual stress, and deformation. These effects can reduce dimensional accuracy, manufacturing stability, fatigue resistance, and service reliability. This review systematically examines residual-stress and deformation behavior in MAM from the perspectives of formation mechanisms, influencing factors, measurement and prediction methods, mitigation strategies, and service-related consequences. The temperature gradient, mechanical constraint, and phase transition mechanisms are discussed as quantitatively coupled rather than independent processes. Comparative attention is given to process-specific differences, alloy-dependent thermophysical and metallurgical behavior, multi-track and multi-material interactions, and complex geometries. Destructive and non-destructive measurement techniques are compared in terms of penetration depth, spatial resolution, uncertainty, and cross-validation. Thermo-mechanical finite element, inherent strain, analytical, reduced-order, machine-learning, physics-informed, and digital-twin approaches are evaluated according to accuracy, efficiency, transferability, and applicability. Mitigation strategies are further compared considering residual-stress reduction, deformation control, manufacturing cost, and mechanical-property retention. Finally, challenges associated with uncertainty quantification, service environments, post-machining stress redistribution, and closed-loop control are identified. This review provides an integrated framework for selecting measurement, prediction, and mitigation approaches for reliable and high-precision MAM.