Research Progress on Post-processing Technologies for Complex Surfaces of Additively Manufactured Metallic Materials

XU Zhanzhao; WANG Bing; LIU Zhanqiang; ZHAO Jinfu; LI Liangliang; SONG Qinghua

doi:10.16490/j.cnki.issn.1001-3660.2026.19.014

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Surface Technology ›› 2026, Vol. 55 ›› Issue (19) : 156-181. DOI: 10.16490/j.cnki.issn.1001-3660.2026.19.014

Surface and Interface Strengthening Technology

Research Progress on Post-processing Technologies for Complex Surfaces of Additively Manufactured Metallic Materials

XU Zhanzhao^1,2,3, WANG Bing^1,2,3,*, LIU Zhanqiang^1,3,4, ZHAO Jinfu^1,2,3, LI Liangliang⁵, SONG Qinghua^1,2,3

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Abstract

High-quality surface processing is a common and critical technology to ensure the service performance and service life of equipment components. Additive manufacturing (AM) technology enables the fabrication of metal parts with complex geometric structures, however, owing to the intrinsic characteristics of significant temperature gradients, repeated melting of the feedstock, and ultra-rapid cooling rates during the additive manufacturing of metallic materials, the fabricated parts are prone to issues including high surface roughness (with prominent spheroidization phenomena), microstructural defects, and residual tensile stress concentration, which impair the mechanical properties and service performance of the parts, rendering them unable to meet the practical application specifications. Although the surface quality of materials can be optimized to a certain extent by controlling the quality of additively manufactured powder or process parameters, there is a gap from the service requirements of the parts. To ensure the performance of the formed material, surface post-processing is generally required to enhance the surface integrity of the parts. This paper aims to review the influences of different post-processing technologies on the surface geometric characteristics, physical metallurgical properties, and mechanical properties of AM parts, and explore efficient post-processing technologies for improving the comprehensive technical indicators of part surface integrity. Firstly, based on a summary of the surface integrity characteristics of AM metal parts with complex structures, the principles of four surface polishing technologies (including chemical polishing, electrochemical polishing, abrasive flow polishing, and laser polishing) and their effects on improving the surface geometric properties of parts are analyzed. Additionally, the improvement effects of surface strengthening post-processing methods (such as heat treatment, cavitation peening, and laser shock peening) on the surface physical metallurgical properties and mechanical properties of parts are summarized. Secondly, limitations of single post-processing technologies in improving the surface integrity of complex structures of additively manufactured metallic materials are explored, together with their failure to achieve a balanced compromise between the surface integrity of AM metallic materials and processing uniformity. For instance, conventional polishing processes can merely refine surface topography and reduce surface roughness yet fail to mitigate residual tensile stress or optimize microstructure. Thus, it is imperative to explore the implementation of synergistic coupling of two or more post-processing technologies to realize the comprehensive enhancement of surface integrity for complex structures of AM metallic materials. This section elaborates on the development status, technical advantages, and feasibility of two categories of hybrid post-processing technologies, namely sequential hybrid and simultaneous hybrid post-processing. A particular focus is placed on the cavitation peening- electrochemical polishing hybrid post-processing method, hydrodynamic cavitation abrasive flow machining and ultrasonic cavitation abrasive machining technology. Finally, the existing problems in the research of post-processing technologies for complex surfaces of additively manufactured metallic materials are summarized, which are limited to experimental methods and empirical optimization of process parameters, with deficiencies in theoretical modeling, processing mechanisms, and process applications. The future research directions for high-quality and high-efficiency surface post-processing technologies are summarized and prospected, with focus on the physical mechanisms of multi-energy field on surface integrity evolution, the uniformity and stability of complex structure surface improvement, and dynamic monitoring and parameter adaptive adjustment in the surface post-processing process.

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surface integrity / post-processing technology / composite treatment process / additive manufacturing / metallic materials

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XU Zhanzhao, WANG Bing, LIU Zhanqiang, ZHAO Jinfu, LI Liangliang, SONG Qinghua. Research Progress on Post-processing Technologies for Complex Surfaces of Additively Manufactured Metallic Materials[J]. Surface Technology. 2026, 55(19): 156-181

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Funding

National Nature Science Foundation of China (52522509, 52175420); Young Elite Scientists Sponsorship Program of China Association for Science and Technology (YESS20210009); Major Basic Research Project of Shandong Natural Science Foundation (ZR2024ZD43)