Hybrid wire arc additive-milling subtractive manufacturing (HWAAMS) is an effective method for the near net formation of complex structures by using the two processes alternately. The effects of milling width (a_e) on the surface residual stress and the influence of milling thickness (t) on tensile anisotropy of the HWAAMS were studied using Al5Si aluminum alloy. The mean surface residual stress of HWAAMS in the middle dropped by 93 % relative to WAAM when the a_e was 0.4 mm. The tensile elongation anisotropy could be controlled within 5 % when the t < 0.4 mm. However, the anisotropy in the ultimate tensile strength gradually increased to 8.3 % when the t was 0.8–1.6 mm. These results showed that milling-induced compressive stress contributed the most to reduce residual stress, and was induced by burnishing between the cutter and the milling surface. The milling-induced compressive stress reduced the surface residual stress and removed the inside maximum stress point by offsetting the initial residual tensile stress. This caused the remaining material with a previous initial residual stress to reach a new equilibrium at various milling depths that resulted in the changes mentioned above. Furthermore, milling decreased the fusion line spacing between the deposition layers that caused a dense and parallel distribution along the building direction rather than the usual WAAM shape that runs through the cross-section along the feeding direction. This caused a tensile anisotropy increase as the t increased because the stress concentration readily formed at the fusion line. These results are significant to understand the additive-subtractive synergistic effects in the HWAAMS.

混合电弧附加铣削减薄制造（HWAAMS）是通过交替使用这两个过程来形成复杂结构的近乎净形成的有效方法。使用Al5Si铝合金研究了铣削宽度（a _e）对表面残余应力的影响以及铣削厚度（t）对HWAAMS拉伸各向异性的影响。当a _e为0.4 mm时，HWAAMS的平均表面残余应力相对于WAAM降低了93％。当t＜0.4mm时，拉伸伸长率各向异性可以控制在5％以内。但是，当t时，极限抗拉强度的各向异性逐渐增加到8.3％。为0.8-1.6毫米。这些结果表明，铣削引起的压应力最大程度地降低了残余应力，并且是由刀具与铣削表面之间的打磨引起的。铣削引起的压应力通过抵消初始残余拉应力来减小表面残余应力并消除内部最大应力点。这导致具有先前初始残余应力的剩余材料在各种铣削深度处达到新的平衡，从而导致上述变化。此外，铣削减小了沉积层之间的熔合线间距，从而导致沿构造方向密集且平行的分布，而不是沿进料方向贯穿横截面的常规WAAM形状。这导致了拉伸各向异性的增加。t增大是因为在熔合线上容易形成应力集中。这些结果对于理解HWAAMS中的加减协同效应具有重要意义。