Ultrasonic field-assisted metal additive manufacturing (U-FAAM): Mechanisms, research and future directions

Metal additive manufacturing (AM) is a disruptive technology that provides unprecedented design freedom and manufacturing flexibility for the forming of complex components. Despite its unparalleled advantages over traditional manufacturing methods, the existence of fatal issues still seriously hinders its large-scale industrial application. Against this backdrop, U-FAAM is emerging as a focus, integrating ultrasonic energy into conventional metal AM processes to harness distinctive advantages. This work offers an up-to-date, specialized review of U-FAAM, articulating the integrated modes, mechanisms, pivotal research achievements, and future development trends in a systematic manner. By synthesizing existing research, it highlights future directions in further optimizing process parameters, expanding material applicability, etc., to advance the industrial application and development of U-FAAM technology.