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The accumulation of residual stress during welding and additive manufacturingis an important effect that can significantly anticipate the workpiece failure.In this work we exploit the physical and analytical transparency of a 1.5Dmodel to show that the deposition of thermally expanded material onto anelastic substrate leads to the accumulation of strain incompatibility. Thisfield, which is the source of residual stress in the system, introduces memoryof the construction history even in the absence of plastic deformations. Themodel is then applied to describe the onset and the progression of residualstresses during deposition, their evolution upon cooling, and the fundamentalrole played by the velocity of the moving heat source.

Strain incompatibility as a source of residual stress in welding and additive manufacturing