A Comprehensive Review on Failure Aspects of Additive Manufacturing Components under Different Loading Conditions

Understanding the underlying cause of the failure mechanisms of additive manufacturing (AM) components is essential for developing fatigue-resistant materials and improving the performance of AM components. This comprehensive review article discusses the mechanical failures of AM components including tensile, fatigue, and fracture, which arise due to microstructural heterogeneity influenced by various factors such as porosity, lack of fusion, thermal gradient, powder characteristics, and bonding mechanism. The article also explores the optimization of processing parameters such as beam size, power, temperature, and material deposition rate to enhance resistance against these failures. Additionally, it discusses the various post-processing techniques to mitigate the defects-related issues of additive manufacturing processes, and finally, future research perspectives are pointed out. The comprehensive review contributes to understanding the mechanical and microstructural aspects of the failure mechanisms of the AM components.