The accurate determination of residual stresses has a crucial role in understanding the complex interactions between microstructure, mechanical state, mode(s) of failure, and structural integrity. Moreover, the residual stress management concept contributes to industrial applications, aiming to improve the product's service performance and life cycle. In this regard, the industry requests rapid, efficient, and modern methods to identify and control the residual stress state. This review article contains three main sections. The first section covers different residual stress determination methods and reports the advancements over the recent decade. The second section includes the role of residual stresses in the performance of a broad range of materials including metallic alloys, polymers, ceramics, composites, and biomaterials. This is presented by classifying different science areas dealing with residual stresses into two main groups, including “origins” and “effects” of residual stresses. The range of topics covered are “welding, machining, curing/cooling, and spray coating processes,” “medical and dental sciences,” and “fatigue and fracture mechanisms.” The third section summarizes various strategies to effectively control residual stresses through different manufacturing procedures. It is hoped that the data provided herein serves as a valuable up‐to‐date reference for engineers and scientists in the field of residual stress.

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This paper closely evaluates the interfacial bonding mechanism between titanium particles deposited on an aluminum alloy substrate by cold gas spraying followed by friction-stir processing (FSP). After cold spraying and FSP modification, the produced Al/Ti interface was studied using focus ion beam-transmission electron microscopy (FIB-TEM) analysis and auger electron spectroscopy. Formation of a well-bonded titanium aluminide reaction layer was observed at the interface with a thickness in the range of 10-20 nm and a coherent interface associated with an inter-diffusion distance of about 600 nm. The results of this study showed that the physical bonding phenomenon during cold spraying according to the wellknown adiabatic shear instability at the interface can be associated with chemical bonding and formation of an intermetallic layer at the interface during FSP modification. This is aided by the induced thermo-mechanical processing and deformation-assisted solid-state diffusionbased reactions. Also, these possible interfacial bonding and intermetallic layer formation mechanisms were discussed based on the inter-diffusion of elements at the Al/Ti interface based on the well-established Boltzmann-Matano theory and kinetics models correlated with experimental observations. The main findings of this research highlight the role of FSP on the performance of cold spray coatings as a post-processing technique to promote densification and homogenization during processing by promoting nano-scale interfacial mechanisms and chemical bonding at the interface.

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