Residual stress management through closed loop control

An additive manufacturing system comprising:

• an energy delivery device configured to deliver energy to a build surface of an additively-manufactured component to form a melt pool in the build surface of the component;
• a powder delivery device configured to direct a powder stream toward the melt pool;
• one or more thermal sensors configured to measure a temperature of a first portion of the additively-manufactured component and a second portion of the additively manufactured component;
• and
• a computing device configured to:
• receive data indicative of the temperature of the first portion of the additively-manufactured component from the one or more thermal sensors captured at a first point in time and data indicative of the temperature of the first portion captured at a second point in time;
• receive data indicative of a temperature of the second portion of the additively-manufactured component from the one or more thermal sensors captured at the first point in time and data indicative of a temperature of the second portion captured at the second point in time;
• determine a residual stress of the additively-manufactured component based at least partially on the received data indicative of the temperature of the first portion of the additively-manufactured component and the received data indicative of the temperature of the second portion of the additively-manufactured component;
• predict final dimensions of the additively-manufactured component based at least partially on the determined residual stress of the additively-manufactured component;
• and
• control the energy deliver device or the powder deliver device based on the predicted final dimensions of the additively-manufactured component.