Metal additive manufacturing is experiencing rapid growth due to its ability to produce intricately designed parts with customized features for diverse applications. However, the as-built configuration of these parts often exhibits insufficient and poor surface quality. Various imperfections and defects, such as the staircase effect resulting from layer-by-layer deposition, partially fused feedstock material, spatters, balling effects, and inadequate fusion, contribute to notably irregular surface morphology. This elevated surface roughness poses a significant challenge, limiting the potential applications of additive manufactured parts in areas such as fatigue performance, dimensional accuracy, wear and scratch resistance, and aesthetics. In response to these challenges, the manufacturing landscape is transforming by introducing Hybrid Additive Manufacturing (HAM) processes. These processes aim to minimize manufacturing costs while enhancing mechanical properties and surface quality by integrating additive manufacturing with conventional production methods. HAM represents a synergistic blend of techniques, producing a cumulative effect greater than the sum of its individual processes. Hence, this paper offers a comprehensive review of the current state and future prospects of hybridization in metal additive manufacturing, shedding light on innovative strategies to overcome surface quality limitations and optimize the overall performance of additively manufactured parts.

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Hybridization in Metal Additive Manufacturing: Current Status and Future Prospectives

  • Ajithkumar Sitharaj,
  • B. Arulmurugan,
  • N. Karthi,
  • M. S. Dhanushh,
  • S. R. Deepak,
  • M. Ajay

摘要

Metal additive manufacturing is experiencing rapid growth due to its ability to produce intricately designed parts with customized features for diverse applications. However, the as-built configuration of these parts often exhibits insufficient and poor surface quality. Various imperfections and defects, such as the staircase effect resulting from layer-by-layer deposition, partially fused feedstock material, spatters, balling effects, and inadequate fusion, contribute to notably irregular surface morphology. This elevated surface roughness poses a significant challenge, limiting the potential applications of additive manufactured parts in areas such as fatigue performance, dimensional accuracy, wear and scratch resistance, and aesthetics. In response to these challenges, the manufacturing landscape is transforming by introducing Hybrid Additive Manufacturing (HAM) processes. These processes aim to minimize manufacturing costs while enhancing mechanical properties and surface quality by integrating additive manufacturing with conventional production methods. HAM represents a synergistic blend of techniques, producing a cumulative effect greater than the sum of its individual processes. Hence, this paper offers a comprehensive review of the current state and future prospects of hybridization in metal additive manufacturing, shedding light on innovative strategies to overcome surface quality limitations and optimize the overall performance of additively manufactured parts.