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<p>Metal additive manufacturing (MAM) offers remarkable advantages in fabricating complex components, yet its industrial-scale deployment is hindered by critical bottlenecks including residual stress, microstructural defects, and mechanical property anisotropy. To address these challenges, physical field-assisted metal additive manufacturing (PFAMAM) has emerged as a promising solution, leveraging external physical fields–mechanical, thermal, ultrasonic, and electromagnetic–to actively regulate the manufacturing process. This review systematically examines four categories of auxiliary technologies and establishes a four-dimensional analytical framework: physical field type – interaction mechanism – microstructure regulation – performance output. This framework enables quantitative comparison of regulatory efficiency, penetration depth, and applicability boundaries across different physical fields. Analysis reveals that through coordinated regulation of molten pool dynamics and solidification behavior, these physical fields effectively suppress defects, refine grains, and optimize stress distribution. Furthermore, this work outlines future development directions, including multi-field synergy, intelligent regulation, and standardization, aiming to provide systematic theoretical guidance and technical references for the high-performance manufacturing of MAM components.</p>

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Physical field-assisted metal additive manufacturing technology: research progress and prospects

  • 期刊论文

  • 发表日期：

    2026年5月25日

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  • Junhua Wang,
  • Junhang Wang,
  • Luhaotian Feng,
  • Dongbo Lu,
  • Mingxin Liu,
  • Yuanming Mao,
  • Liaoyuan Chen,
  • Kun Li,
  • Bingjing Guo,
  • Ruijie Gu

摘要

Metal additive manufacturing (MAM) offers remarkable advantages in fabricating complex components, yet its industrial-scale deployment is hindered by critical bottlenecks including residual stress, microstructural defects, and mechanical property anisotropy. To address these challenges, physical field-assisted metal additive manufacturing (PFAMAM) has emerged as a promising solution, leveraging external physical fields–mechanical, thermal, ultrasonic, and electromagnetic–to actively regulate the manufacturing process. This review systematically examines four categories of auxiliary technologies and establishes a four-dimensional analytical framework: physical field type – interaction mechanism – microstructure regulation – performance output. This framework enables quantitative comparison of regulatory efficiency, penetration depth, and applicability boundaries across different physical fields. Analysis reveals that through coordinated regulation of molten pool dynamics and solidification behavior, these physical fields effectively suppress defects, refine grains, and optimize stress distribution. Furthermore, this work outlines future development directions, including multi-field synergy, intelligent regulation, and standardization, aiming to provide systematic theoretical guidance and technical references for the high-performance manufacturing of MAM components.