Table 1:

Selected thermomechanical modeling literature, the authors’ overall strategy, and major outcomes.

Process	Ref	Material	Energy Source	Element Scheme	Analysis	Major Outcomes
DED Powder Feed	[70]	Ti6Al4V	Ellipsoidal	Hybrid	3D-Uncoupled, Pan Computing	Incorporating forced convection boundary conditions in the model improves temperature and corresponding residual stress estimates.
	[64]	Ti6Al4V	Ellipsoidal	Quiet	3D-Coupled, Not Listed	When printing on cantilevered plate for model verification, plate will tend to bend upwards.
	[57]	Inconel 718 + Ti6Al4V	Gaussian	Not Specified	3D-Uncoupled, ABAQUS	For printing tall structures, reducing the layer thickness can increase distortion, while simultaneously decreasing residual stresses.
DED Wire Feed	[76,77]	Mild Steel Wire	Gaussian	Inactive	3D-Coupled, ABAQUS	Residual stress across a line of deposit is uniform with low affect from previous layers’ stress profile.
	[123]	Steel Wire	Ellipsoidal	Quiet	3D-Coupled, MSC-Marc	Final deposition path can have significant effect on the final residual stresses
	[68]	Inconel 718 Wire	Uniform Source	Inactive	3D-Coupled	Using a large-strain plasticity model can result in higher accuracy, but also increases computational cost significantly.
PDF EBM	[81]	Ti6Al4V	Gaussian	None-Single Scan	3D-Coupled, ABAQUS	Increase in bed preheat temperature as high as 50°C can reduce residual stresses by ~20%.
	[124]	Rene 80 (Ni-based superalloy)	Gaussian	None-Single Scan	3D-Coupled, SYSWELD	Yield stresses were easily achieved after heat source passing.
	[84]	Inconel 718	Effective (Temp-Driven)	Inactive	3D-Uncoupled, ABAQUS	Preheating substrate prior to printing will reduce the magnitude of the residual stresses developed.
PBF SLM	[65]	AlSi10Mg	Gaussian	Hybrid	3D-Uncoupled, ABAQUS	Relatively long laser exposure time (slower scan speeds) will tend to induce a much larger residual stress field.
	[73]	Stainless Steel 316	Gaussian	Inactive	3D-Indirectly Coupled-FE ANSYS	Residual stress calculation is reduced at high temperature when temperature-dependent thermophysical properties are accounted for.
	[82]	Ti6Al4V	Gaussian	Inactive	3D-Coupled, MSC-Marc	No significant variation in residual stresses among different “square pattern” scan strategies, but significant variation in directional stresses.
	[125]	Inconel 718	Double Ellipsoidal	Quiet	Thermal FE-Only Pan Computing	Assuming powder layer is insulator can significantly overpredict temperatures in component.
	[62]	Inconel 718	Ellipsoidal	Hybrid	3D-Weakly Coupled Pan Computing	Rotating scan patterns can homogenize residual stress fields.
	[126]	Fe-based	Gaussian	Inactive	3D-Coupled ABAQUS	Equivalent heat source method used from single-layer simulated temperature field, reduced computational cost and maintained accuracy.
	[71]	Inconel 718	Gaussian	Quiet	3-D Coupled, ABAQUS	Rotating 45° scan patterns produce the lowest planar stresses and deformation when compared with other scanning strategies