Surface Stress Research Articles

Stress Release of Zincophilic N-Doped Carbon@Sn Composite on High-Curvature Surface of Zinc Foam for Dendrite-Free 3D Zinc Anode.

Commercial 3D zinc foam anodes with high deposition space and ion permeation have shown great potential in aqueous ion batteries. However, the local accumulated stress from its high-curvature surface exacerbates the Zn dendrite issue, leading to poor reversibility. Herein, we have employed zincophilic N-doped carbon@Sn composites (N-C@Sn) as nano-fillings to effectively release the local stress of high curvature surface of 3D Zn foams toward dendrite-free anode in aqueous zinc ion battery (AZIB). These electronegative and conductive N-C@Sn nano-fillings as supporters can provide a highly zincophilic channel for initial Zn nucleation and reduce local current density for regulating Zn deposition. Uniform Zn deposition further assists homogenous stress distribution on the platting surface, which gives a positive feedback loop to improve anode reversibility. As a result, zinc foam with N-C@Sn composite (ZCSn Foam) symmetric cell achieves a long cycle lifespan of 1100h at 0.5mA cm-2, much more than that of Zn Foam (∼80h lifespan). The full cell ZCSn Foam||MnO2 exhibits remarkable reversibility with 67% retention after 1000 cycles at 0.8 A g-1 and 76% after 1600 cycles at 2 Ag-1. This 3D-constructing strategy may offer a promising and practical pathway for metal anode application.

Cell integrity limits ploidy in budding yeast

Abstract Evidence suggests that increases in ploidy have occurred frequently in the evolutionary history of organisms and can serve adaptive functions to specialized somatic cells in multicellular organisms. However, the sudden multiplication of all chromosome content may present physiological challenges to the cells in which it occurs. Experimental studies have associated increases in ploidy with reduced cell survival and proliferation. To understand the physiological challenges that suddenly increased chromosome content imposes on cells, we used S. cerevisiae to ask how much chromosomal DNA cells may contain and what determines this limit. We generated polyploid cells using 2 distinct methods causing cells to undergo endoreplication and identified the maximum ploidy of these cells, 32–64C. We found that physical determinants that alleviate or exacerbate cell surface stress increase and decrease the limit to ploidy, respectively. We also used these cells to investigate gene expression changes associated with increased ploidy and identified the repression of genes involved in ergosterol biosynthesis. We propose that ploidy is inherently limited by the impacts of growth in size, which accompany whole-genome duplication, to cell surface integrity.

The droplet dynamics of asymmetrical impingement on moving ridged surface.

The depth of research into the mechanism of droplet impacting structured surfaces dictates the efficacy of their applications. The impact stress generated when a droplet impacts a surface is a pivotal factor influencing the efficiency of surface applications, ultimately determining the extent of surface wear. Despite the systematic examination of impact force, there remains a scarcity of research on impact stress and its mitigation strategies. Consequently, the objective of this study is to delve into the mechanisms that reduce maximum impact stress following the introduction of aerodynamic boundary layer and structural design. Based on experimental investigations, we examined the dynamic behavior of droplet impacting moving ridged surface with varying offset ratios across different tangential and normal Weber numbers. This study emphasizes the impact behavior phase diagram, droplet spreading length, and other relevant parameters. Furthermore, we systematically analyzed the evolution of the flow field and surface stress during the impact process benefit from a numerical simulation of a two-phase laminar flow model. This study shows that the impact of droplets on moving ridged surfaces significantly influences stress reduction, with a focus on asymmetric droplet impacts. The research establishes a phase diagram for droplet impact behaviors across varying tangential Weber number (Weτ), normal Weber number (Wen) and offset ratio (χ), and some unified models about the maximum spreading diameter (Dmax) of the droplet are obtained based on the above variables. Besides, a model based on Prandtl's boundary layer theory emphasizes and proves the positive effect of the introduction of air layer on the reduction of maximum impact stress. Notably, the offset ratio significantly influences stress distribution, the maximum impact stress shows a non-monotonic change from increasing first to decreasing as χ increases considering the rotation of droplet. This research contributes valuable insights into surface design strategy for enhancing the resistance to droplet impact wear. These findings have broad implications for industrial applications where managing droplet impingement is crucial.

The unseen perils of oral-care products generated micro/nanoplastics on human health.

The extensive use of plastics in modern dentistry, including oral care products and dental materials, has raised significant concerns due to the increasing evidence of potential harm to human health and the environment caused by the unintentional release of microplastics (MPs) and nanoplastics (NPs). Particles from sources like toothpaste, toothbrushes, orthodontic implants, and denture materials are generated through mechanical friction, pH changes, and thermal fluctuations. These processes cause surface stress, weaken material integrity, and induce wear, posing health risks such as exposure to harmful monomers and additives, while contributing to environmental contamination. MPs/NPs released during dental procedures can be ingested, leading to immune suppression, tissue fibrosis, and systemic toxicities. The gut epithelium absorbs some particles, while others are excreted, entering ecosystems, accumulating through the food chain, and causing ecological damage. Although analytical techniques have advanced in detecting MPs/NPs in oral care products, more robust methods are needed to understand their release mechanisms. This review explores the prevalence of MPs/NPs in dentistry, the mechanisms by which MPs/NPs are released into the oral environment, and their implications for human and ecological health. It underscores the urgency of public awareness and sustainable dental practices to mitigate these risks and promote environmental well-being.

Increasing the post-repair resource of the wheels attachment bolts of transport machinery

Abstract. Problem. The state of war in our country and a significant reduction in the production of new vehicles exacerbated the problem of increasing their operational resource due to repairs. Improving the quality and increasing the efficiency of transport vehicles involves, first of all, the fight against wear and tear, because the reason for their premature failure (from 75 to 90%) is significant wear and tear of parts. A significant number of parts of the main structural units of vehicles are exposed to cyclic loads, so it is quite reasonable to pay attention to the issue of increasing the fatigue strength of products. Considering the significant shortage and high cost of spare parts, an expedient and economically beneficial solution to these problems is the restoration and strengthening of the surface layers of products during repair The parts that mostly fail prematurely and require repair using rational methods of recovery include the bolts of fastening the wheels of buses - a very common vehicle that is intensively operated in very difficult conditions. The development of effective technological processes for the restoration of bolts with a simultaneous increase in the post-repair resource at the lowest costs is definitely an urgent issue, because it will prevent another possible premature failure in operation Goal. The purpose of the work is to restore and increase the post-repair resource of the bolts for fastening the disks of the rear wheels of the bus. Methodology. The subject of the study were the serial bolts for fastening the discs of the rear wheels of the bus made of 40X steel after quenching and tempering at 500-550º C with a trostite-bainite structure and a hardness of 35-37 НРС. For vibro-arc surfacing, electrode wire Нп-30ХГСА with a diameter of 1.2 mm was used. Food carbon dioxide was used as a protective gas, and a 5% solution of soda ash in water was used as an accelerating coolant. After surfacing, the surface was subjected to bombardment with low-energy (up to 3 keV) titanium ions in an argon environment at the Bulat - 3t installation. After the specified methods of bolt processing, the roughness and surface profile were evaluated, the microstructure was studied, and the mechanical properties were determined. The strength limit of the slotted part of the bolt was determined using special samples on the CD10 universal machine (made in Germany). Cyclic tests of welded samples were carried out according to the scheme "tension during rotation of the cantilever-loaded sample" on the UMP-02 machine. Tensile tests were performed according to standard methods. Originality. To increase the cyclic durability and wear resistance of bolts, a modern method of surface modification was used - ion bombardment with low-energy ions (without coating), which made it possible to strengthen the surface layer without losing plasticity. An increase in the resource was achieved due to a change in the state of the surface (obtaining ultrafine crystalline nano-sized grain, healing of surface stress concentrators), and a change in the mechanism of plastic deformation - from dislocation to rotational with grain-boundary sliding of ultra-fine grains. Practical value. The recommended mode of vibro-arc surfacing provides surface hardness for the possibility of further mechanical processing without additional thermal weakening, which increases the cost-effectiveness of the process of compensation of the worn surface layer. Modification of the surface by ion brombarbing after surfacing made it possible to increase the cyclic durability by 2 times, significantly increase the static strength without loss of plasticity, and increase the hardness to ensure wear resistance.

Geometric generation and meshing characteristics analysis of a new S-shaped gear drive

A new type of S-shaped gear drive with a tooth profile combining involute and circular-arc curves is proposed in this paper. Tooth profile design includes convex involute, convex circular-arc, concave involute, and concave circular-arc curves is carried out. Geometric generation and mathematical model of tooth surfaces of the S-shaped gear are established based on imaginary rack method. Utilizing Hertz contact theory, the calculation formula of contact stress of tooth surfaces is provided. Furthermore, simulation analysis of contact stress based on finite element method under various working conditions is studied using ANSYS/Workbench software. And the comparisons of stress results with general involute gear are also provided. Dynamic characteristics analysis of the generated tooth surfaces is put forward using the established virtual prototype. Normal contact force, circumferential force, axial force and radial force of tooth surfaces both S-shaped gear and involute gear are analyzed. Research results show that the developed S-shaped gear has better transmission performance than involute gear. Further study on dynamic analysis and manufacturing method will be carried out.

Analytical solutions for bending of piezoelectric micro-beam sensors under surface stress effects

Analytical solutions for bending of piezoelectric micro-beam sensors under surface stress effects

Numerical Simulation and Experimental Study on Construction Forming of Cable-Stayed Tensioned Metal Thin Sheet Structure

This study investigates the construction methodology of large-span cable-stayed tensioned metal thin-sheet structures, introducing the “integrated enclosure and load-bearing” design concept. By applying in-plane prestress, the out-of-plane stiffness of the metal thin sheet is effectively enhanced, enabling it to simultaneously serve as an enclosure and a load-bearing component. Through experimental studies and finite element analysis, the study systematically examines the effects of various construction methods on internal forces and displacements. The tensioning of back cables is identified as the safest and most efficient construction method. Subsequently, through simulations of a three-span structure and tensioning forming tests, the research examines displacement, stress, and cable force distribution patterns, demonstrating that increases in the tensioning level result in corresponding increases in sheet surface stress, cable forces, and displacements. The structure exhibits a concave middle section, upward curvatures at both ends, and outward-leaning end columns. Structural members with lower cable forces show minimal impact on displacement and are therefore identified as suitable targets for design optimization. This study offers a theoretical foundation and practical engineering insights to guide the optimization of design and construction for cable-stayed tensioned metal thin-sheet structures.

Design and analysis of thickened acoustic phase reversal Fresnel lens with high-focusing performance

ABSTRACT The accurate measurement of the contact stress of an aero-engine rotor mating surface is crucial for aviation safety. The focusing performance of ultrasonic lenses directly determines the accuracy of contact stress measurement. Phase reversal Fresnel zone plate (PR-FZP) is a new ultrasonic focusing lens suitable for contact stress measurement. A thickened phase reversal Fresnel zone lens (TPR-FZL) is proposed to improve the concentration ability. The lens replaces the path of sound waves travelling through the liquid with the Fresnel lens material, which reduces the energy loss of sound waves in the liquid and the interface of different materials, thus increasing the focus sound energy. The results showed that TPR-FZL, made of polymethyl pentene (PMP) and polyethene (PE), had relatively higher focal sound intensity. The larger the diameter of the piezoelectric plate, the stronger the focusing ability of TPR-FZL. When the material of TPR-FZL is PMP, the diameter of the piezoelectric plate of the transducer is 25 mm, TPR-FZL is the intermediate transmission type, and the thickness of the body is 35 mm, the focusing ability of TPR-FZL is the strongest. This study is of great significance for accurately measuring the contact stress on the mating surface of aero-engine rotors.

Surface Stress Regulation and Cutting Performance of the TiN/TiAlN-Coated Tool in Clean LN2 Cutting Process

Surface Stress Regulation and Cutting Performance of the TiN/TiAlN-Coated Tool in Clean LN2 Cutting Process

Synthesis of SiO2 nanoparticles using the Stöber method and their self-assembly into liquid photonic crystals for surface stress sensing applications

Synthesis of SiO2 nanoparticles using the Stöber method and their self-assembly into liquid photonic crystals for surface stress sensing applications

Unraveling the Impacts of Submesoscale Thermal and Current Feedbacks on the Low-Level Winds and Oceanic Submesoscale Currents

Abstract In this study, high-resolution coupled ocean–atmosphere simulations are performed over the Gulf Stream to investigate the influence of submesoscale [O(10) km] thermal feedback (TFB) and current feedback (CFB) on the low-level atmosphere and the oceanic submesoscale kinetic energy (SKE). At the submesoscale, TFB and CFB exhibit constructive and destructive effects on wind and surface stress, making this a more complex problem than for the mesoscale [O(100) km]. This coinfluence alters classical coupling coefficients, posing a challenge to isolate individual coupling mechanisms. Here, the feedbacks are isolated separately by removing their imprint on the air–sea coupling fields in dedicated simulations. Both submesoscale TFB and CFB lead to a damping of the SKE. CFB causes eddy killing by drag friction between currents and the atmosphere. However, while eddy killing should be more efficient than its mesoscale counterpart due to a weaker wind response (less re-energization), its effect is hampered by an energization from TFB and by the highly transient nature of submesoscale flow, resulting in a modest 10% reduction in SKE. TFB also contributes to a reduction of SKE, mainly by causing a potential energy sink, associated with turbulent heat fluxes, especially at scales < 10 km. The potential energy sink affects SKE through a decrease of baroclinic energy conversion although this is slightly modulated by an increase in Ekman pumping by submesoscale CFB. Our results emphasize the importance of considering both TFB and CFB at the submesoscale and highlight the limitations of mesoscale CFB parameterizations for submesoscale applications. Future parameterizations should be scale-aware and account for both TFB and CFB effects on momentum and heat fluxes.

Effects of Beads and Shot Peening Intensity on the Surface Integrity and Fatigue Performance of a Stainless Gear Steel

Shot peening was performed on stainless gear steel using multiple kinds of beads at multiple intensities. The effects of shot peening on surface integrity and the rotational bending fatigue performance were tested with the crack origin location observed. The results showed that the average surface roughness increases from Sa0.408 μm to Sa1.165 μm as the shot peening intensity increases, which does not necessarily lead to an increase in surface stress concentration coefficient. The compressive residual stress profile and the depth of the hardened layer increase with the increase of shot peening intensity. During ceramic bead peening, the fatigue improvement, with a maximum of 25 times, increases with the raise of intensity (0.06–0.20 mmA), while the fatigue improvement decreases when intensity (0.2–0.30 mmA) increases using cast steel shot. Based on ceramic shot peening, a method was proposed to predict the origin location of rotational bending fatigue cracks of gear stainless steel, in which the effects of surface stress concentration, compressive residual stress, and external load introduced were all considered. By using the superposition method of external load and residual stress, the maximum actual stress corresponding depth is obtained, which is the origin position of the rotational bending fatigue crack.

Fabrication of micro holes with confined pitting corrosion by laser and electrochemical machining: pitting corrosion formation mechanisms and protection method

Laser and electrochemical hybrid machining (LECM) combines the advantages of high efficiency of laser processing and high surface quality of electrochemical machining and has been employed to process deep micro holes with high surface quality, high precision, and efficiency. However, surface pitting corrosion occurs around the entrance of the micro holes drilled by LECM, which deteriorates their surface quality and mechanical properties. This study revealed the mechanism of surface pitting corrosion formation mechanisms during LECM by characterizing surface micromorphology, chemical composition, microstructures, and surface stress. The difference between surface pitting corrosion area during LECM and the stray current corrosion during electrochemical machining was studied. Micro solid metal particles and inner microcavities were observed in micro pits. The depth of the micro pits was greater than that obtained using electrochemical machining. It has been concluded that in LECM, the surface pitting corrosion occurred owing to the enhanced stray current corrosion and the accumulation of solidified melt particles and cavitation microbubbles in the micro pits. Coaxial gas-assisted LECM was also proposed to restrict the surface pitting corrosion area. Experiments and simulations were conducted to verify the feasibility of minimizing the corrosion area using coaxial gas. The surface pitting corrosion area has been decreased by 85.1% at a coaxial gas pressure of 0.1MPa compared with that without coaxial gas assistance. Finally, the radial cooling holes with a diameter of 1.2mm and an aspect ratio of 125:1 in turbine blades with high surface quality were fabricated. This study provides a promising method to fabricate high-aspect-ratio micro-holes with high surface quality and high efficiency.

Fretting Dynamic Contact Analysis of Planetary Gear-Bearing Interference Fit Surface Considering Non-Uniform Interference

Abstract The planetary gear-bearing interference fit surface is prone to fretting slip under alternating torque, which can lead to fretting wear and fatigue failure. However, the current studies often ignore the influence of non-uniform interference on the stress and strain of the fit surface. In this paper, the force analysis of the planetary gear-bearing interference fit surface is carried out based on thick cylinders theory and planetary gear dynamics, and the fretting slip mechanism is explained in detail. Based on the assumption of plane stress, the equation for interference distribution in the circumferential direction of the fit surface is derived. On this basis, a three-dimensional fretting contact model considering non-uniform interference is established and solved by the conjugate gradient method (CGM). The results show that under the action of alternating torque, the fit surface interference is non-uniformly distributed in the circumferential direction, which shows a trend of increasing first and then decreasing. The fretting slip distance decreases first and then increases in the circumferential direction, but the fretting slip curve considering non-uniform interference shows a slip distance of nil in the range where the interference value exceeds the initial value. The model in this paper is more in line with the actual situation, and can provide more accurate theoretical calculation for the planetary gear-bearing interference fit design.

Mechanics analysis and experimental study of ultra-thin chip peeling from pre-stretching substrates

Successful chip peeling from a substrate facilitates the transfer process for obtaining the final functional chips, but remains a challenge in the practical production of ultra-thin chips. Flexible ultra-thin chips are prone to fragmentation during the peeling process, due to their fragility. In this study, a substrate pre-stretching process is introduced to the picking process to achieve a high yield of chip peeling, and this process is explored via modelling and experiments. The chip–adhesive pre-stretched substrate structure is modelled, involving both multi-needle ejection and vacuum suctioning, within the framework of Timoshenko’s beam theory. The theoretical analysis is validated using finite element analysis to compare the surface stress distribution on the chip and tip stress within the adhesive layer. During the peeling process, the competitive fracture behaviour of the chip between cracking and peeling is analysed using a dimensionless peeling health index as a metric to assess the health status of the chip. The effects of substrate pre-stretching on the adhesive layer stress, chip layer stress, and peeling health index are analysed. As substrate pre-stretching is found to improve the peeling health index only in the case of needle ejection, but impairs the peeling health index in the case of vacuum suctioning, needle ejection is considered the sole effective peeling method when a substrate pre-stretching process is introduced. Furthermore, through meticulous experimental verification, it is confirmed that pre-stretching of the substrate can significantly improve the success rate of chip peeling.

The fluid mechanics of spray cleaning: when the stress amplification at the contact lines of impacting droplets nano-scraps particles

In spray cleaning, a multitude of small drops, violently accelerated by a high-speed gas stream, strike a dirty surface. This process is extremely effective: very little dirt can resist it. This is true even for dirt particles whose characteristic size is less than 100 nm. Spray cleaning is classically modelled by balancing particle adhesion with either inertial stress or viscous shear near the surface, the latter being calculated using droplet size and velocity as the characteristic length and velocity. This results in dimensionless numbers that are often well below one, suggesting that the mechanical stress exerted on the surface by the drop impact that detaches the particle is not well captured. Using quantitative nanoscale measurements, we show that the remarkable efficiency of spray cleaning results from the forced spreading of each droplet on the surface, which generates an unsteady and inhomogeneous shear confined to a boundary layer entrained in the wake of the liquid–solid contact line. In the very first moments of impact, the boundary layer is extremely thin, yielding a gigantic stress: the contact line of the spreading droplets sweeps all the surface particles away. We propose a quantitative model of spray cleaning based on this unsteady surface stress, which agrees well with (i) experimental data obtained with spray droplets of $34\ \mathrm {\mu }$ m mean radius impacting the surface to be cleaned at a mean velocity ranging between 30 and 70 m s $^{-1}$ and contamination by nanoparticles of varying nature and shape and (ii) data in the literature on spray cleaning.

(Invited) Reaction-Based Microcantilever Sensors

Microcantilevers (MCLs) have proven to be a cost-effective, label-free, and portable analytical technique for the detection of chemical and biological species. The MCL method offers significant benefits, primarily owing to its high sensitivity, which enables the detection of cantilever motion with sub-nanometer precision. Additionally, this method is well-suited for fabrication into a multi-element sensor array, further enhancing its capabilities. Most of the sensors are based on adsorption-induced frequency or surface stress changes of MCLs. Multiple review articles on this concept have been published, but no review has been published summarizing the MCL sensors with a focus on reactions. Other than detecting chemical species, another unique application of MCLs is their ability to characterize the morphology and mechanical properties of materials on a solid-liquid or solid-gas interface during a reaction process. We will review the reaction-based MCL sensors and also their potential applications in monitoring reactions in this short review article.

Stress-Adaptive Binder Based on Shear-Thickening Properties for Highly Expansible LIB Electrodes

In this study, we introduce a novel elastic binder incorporating an automatic stress-control mechanism for Li-ion batteries, particularly focusing on high-capacity electrode materials like silicon (Si) that suffer from significant volumetric expansion during lithiation. This expansion often leads to material degradation and reduced battery life. The design and optimization of elastic binders encapsulating nanoparticles has been one of the attractive approaches to relieving such stress. However, all these types of binders have a possibility of intrinsic detaching under dynamic shear stress conditions from the local surface of the particles in electrode. Although the effective management of the dynamic local stress is one of the essential factors to achieve structural robustness of electrode materials, the real-time automatic change in local stress by binders has not been considered up to now. Therefore, introducing a dynamic stress-adaptive attribute can provide novel insights into the binder characteristics, a domain that remains unexplored to the best of our knowledge.Herein, we present a new type of binder that automatically controls the stress against changes in local surface shear modulus as a new factor of elastic binder properties. As a proof of concept, we selected starch as the main polymer binder because gelatinized starch is a representative shear-thickening fluid which means that the viscoelasticity of the surface can automatically change when under changes in stress. Starch can also create strong interactions with Si particles, therefore, we hypothesized that these characteristics of starch easily dissipate high mechanical stresses during the iterated reaction with huge volume changes of Si.To demonstrate this concept of dynamic stress control, the study focused on the shear-thickening property, where polymers automatically amplify their viscoelasticity in response to local variation in surface stress. It incorporates an innovative stress-control mechanism that can adapt to dynamic local stress changes. Upon removal of the impact force, the shear-thickening materials instantly revert to their original elastic state. The shear-thickening properties have broad application prospects in shock absorption, human body protection, and surface polishing owing to their ability to absorb significant amounts of impact energy. However, they have not yet been adopted for microscale electrode protection.Starch analogs, selected as the primary stress-adaptive elastic binders to validate our approach, exhibited shear-thickening behavior under varying stress levels owing to the unique alignment of their supramolecular bonds. When exposed to forces exceeding their critical shear rate, the starch polymer chains reorient, dissipate stress, and fortify their structure. This behavior suggests that the polymer is more inclined to strengthen than detach from the local surface of the electrode. This mechanism expedites the interactions among the polymer chains, effectively diminishing steric hindrance. Consequently, the stresses induced by the volumetric expansion of individual electrode particles can be mitigated, thereby preventing dynamic local structural breakdown.Three types of starches with different contents of amylose (linear structure) and amylopectin (branched structure) were prepared for the binders, to compare their shear-thickening characteristics in detail. Commercially available potato starch (amylose with long-chain amylopectin, AMLAP), corn starch (amylose with short-chain amylopectin, AMSAP), and waxy maize (only composed of short-chain amylopectin, SAP) were selected to investigate the effect of the different amylose/amylopectin ratios on the stability of the Si electrode. The starches also have ready availability because it is environmentally benign and have a significantly low cost (0.4-0.5 USD kg-1) compared with commercial binder materials, such as CMC (2-5 USD kg-1) and PAA (10-12 USD kg-1).The shear-thickening mechanism was comprehensively investigated using deep-learning based MD simulations and in situ TEM analysis, which determined the optimal conditions for effectively limiting dynamic local surface expansion. Among the starch analogs, the amylose and long-chain amylopectin (AMLAP) binder demonstrated improved high-rate capability (1710 mAh g-1 at 5 C) and superior reversible capacity (2025 and 1493 mAh g-1 after 100 and 500 cycles, respectively, at 1 C) with optimal shear-thickening properties. Furthermore, AMLAP exhibited favorable characteristics for affordable large-scale production. Hence, this study clearly demonstrates that the shear-thickening properties of binders can be considered a new factor in fabricating stable electrodes with extremely expandable materials.

Residual Stress Distribution in Dievar Tool Steel Bars Produced by Conventional Additive Manufacturing and Rotary Swaging Processes.

The impact of manufacturing strategies on the development of residual stresses in Dievar steel is presented. Two fabrication methods were investigated: conventional ingot casting and selective laser melting as an additive manufacturing process. Subsequently, plastic deformation in the form of hot rotary swaging at 900 °C was applied. Residual stresses were measured using neutron diffraction. Microstructural and phase analysis, precipitate characterization, and hardness measurement-carried out to complement the investigation-showed the microstructure improvement by rotary swaging. The study reveals that the manufacturing method has a significant effect on the distribution of residual stresses in the bars. The results showed that conventional ingot casting resulted in low levels of residual stresses (up to ±200 MPa), with an increase in hardness after rotary swaging from 172 HV1 to 613 HV1. SLM-manufactured bars developed tensile hoop and axial residual stresses in the vicinity of the surface and large compressive axial stresses (-600 MPa) in the core due to rapid cooling. The subsequent thermomechanical treatment via rotary swaging effectively reduced both the surface tensile (to approximately +200 MPa) and the core compressive residual stresses (to -300 MPa). Moreover, it resulted in a predominantly hydrostatic stress character and a reduction in von Mises stresses, offering relatively favorable residual stress characteristics and, therefore, a reduction in the risk of material failure. In addition to the significantly improved stress profile, rotary swaging contributed to a fine grain (3-5 µm instead of 10-15 µm for the conventional sample) and increased the hardness of the SLM samples from 560 HV1 to 606 HV1. These insights confirm the utility of rotary swaging as a post-processing technique that not only reduces residual stresses but also improves the microstructural and mechanical properties of additively manufactured components.