Residual stress build-up is a concern in any solid freeform fabrication process involving
successive deposition of uncured or molten material, due to differential contractions caused by
solidification or curing. The most detrimental effect of residual stresses is typically part warping,
which can lead to unacceptable losses in part tolerance. In many processes residual stress build-up
is a fundamental barrier to the consistent manufacture of high-quality artifacts. In this paper, two
methods of measuring residual stresses in parts created by Shape Deposition Manufacturing (SDM)
with microcasting are described. First, a technique for measuring warping in deposited plateshaped
specimens is detailed, which can be used to determine residual stress resultants as well as
to quantify gross effects of processing changes on residual stress magnitudes. Next, x-ray
diffraction procedures are described by which residual stresses in deposited layers can be measured
at discrete in-plane locations as a function of depth. Measured results for 308L stainless steel
deposits determined from each method are interpreted in the context of residual stress modeling
results obtained numerically in a separate research effort. The measured results provide insight
into the effects on residual stress of both the material deposition path and the discrete droplet-bydroplet
nature of the microcasting deposition process. The insights provided here may also be
applicable to other processes involving successive material deposition.Mechanical Engineerin
