Performance-control-orientated hybrid metal additive manufacturing technologies: state of the art, challenges, and future trends

Metal additive manufacturing (AM) technologies have made significant progress in the basic theoretical field since their invention in the 1970s. However, performance instability during continuous processing, such as thermal history, residual stress accumulation, and columnar grain epitaxial growth, consistently hinders their broad application in standardized industrial production. To overcome these challenges, performance-control-oriented hybrid AM (HAM) technologies have been introduced. These technologies, by leveraging external auxiliary processes, aim to regulate microstructural evolution and mechanical properties during metal AM. This paper provides a systematic and detailed review of performance-control-oriented HAM technology, which is categorized into two main groups: energy field-assisted AM (EFed AM, e.g. ultrasonic, electromagnetic, and heat) technologies and interlayer plastic deformation-assisted AM (IPDed AM, e.g. laser shock peening, rolling, ultrasonic peening, and friction stir process) technologies. This review covers the influence of external energy fields on the melting, flow, and solidification behavior of materials, and the regulatory effects of interlayer plastic deformation on grain refinement, nucleation, and recrystallization. Furthermore, the role of performance-control-oriented HAM technologies in managing residual stress conversion, metallurgical defect closure, mechanical property improvement, and anisotropy regulation is thoroughly reviewed and discussed. The review concludes with an analysis of future development trends in EFed AM and IPDed AM technologies. Performance-control-oriented hybrid additive manufacturing was defined as the review scope. Multifarious technologies were classified, summarized and synthesized based on applied objects. Microstructural evolution, mechanical property, and defect elimination were depicted and compared. The synergetic enhancement of strength and ductility was statistically measured and analyzed. Future development trends were predicted on account of the historical outline and research status.