Research Status and Prospects of Additive Manufacturing/Hot Isostatic Pressing Integrated Forming for Difficult-to-Machine Metals
Received date: 2025-11-24
Revised date: 2026-01-06
Online published: 2026-04-02
Supported by
National Natural Science Foundation of China(U22A20192);National Natural Science Foundation of China(52375335);State Key Laboratory of Powder Metallurgy Foundation of Central South University(Sklpm-KF-2025010)
Difficult-to-machine metals typically possess unique physical and mechanical properties, such as high-temperature stability, high specific stiffness, and lightweight characteristics. These metals hold strategic significance for high-end equipment sectors such as aerospace, energy and power, and marine engineering. This study systematically reviews the research progress and development trends in the integrated additive manufacturing/hot isostatic pressing (AM/HIP) forming technology for difficult-to-machine metals. The study focuses on the following four typical materials: (i) Be and its alloys, (ii) Ti2AlNb alloys, (iii) nickel-based superalloys with high Ti/Al content, and (iv) metal matrix composites. This study provides an in-depth analysis of the bottlenecks encountered in conventional processing, such as high forming difficulty, low material utilization, and poor microstructural homogeneity. Furthermore, the study highlights key research breakthroughs in the integrated AM/HIP technology, including multiscale HIP simulation, compensation design methods for capsule structures, AM of high-precision and high-density thin-walled capsules, and AM of high-strength soluble ceramic cores. A comparative analysis is performed on the advantages of the technology in the near-net shaping, microstructural homogenization, and performance optimization of components made from difficult-to-machine materials. Finally, future developments for the technology are outlined, including scientific capsule design, intelligent process control for capsule AM, and synergistic optimization of ceramic core properties. This study provides theoretical support and practical pathways to promote the innovative development of HIP forming technology, expanding its application in the near-final forming of complex components made from difficult-to-machine metals, and offering technical assistance for the manufacturing of core components in key sectors in China, such as aerospace and defense equipment.
SHI Yusheng , CHENG Kun , ZHANG Chengjian , LU Jiahao , LI Wei , ZHANG Lichao , WEI Qingsong , CAI Chao . Research Status and Prospects of Additive Manufacturing/Hot Isostatic Pressing Integrated Forming for Difficult-to-Machine Metals[J]. Acta Metall Sin, 2026 , 62(5) : 770 -784 . DOI: 10.11900/0412.1961.2025.00381
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