Surface integrity and fatigue performance in metal additive manufacturing: a review on surface mechanisms, advanced characterization, and post-processing-induced evolution
Source abstract
Abstract
Purpose This study aims to critically examine the role of surface and near-surface integrity in governing the fatigue performance and surface integrity of metal additive manufacturing (AM) components, with emphasis on surface-driven failure mechanisms. Design/methodology/approach The study investigates recent literature on metal AM surface science by organizing developments around governing surface and subsurface mechanisms rather than individual processing routes. Advances in three-dimensional topography analysis, residual stress characterization and subsurface microstructural evaluation are assessed alongside the influence of post-processing techniques, including machining, heat treatment and mechanical surface treatments. Findings Metal AM processes inherently generate non-equilibrium surface conditions characterized by high roughness, defect populations, residual stress gradients and heterogeneous microstructures, which critically control fatigue crack initiation. Post-processing strategies significantly modify these surface states by reducing defects, strain hardening and redistributing stress, thereby enhancing fatigue resistance. However, limitations remain in quantitatively linking surface metrics to long-term structural performance. Originality/value This review provides a mechanism-oriented and transdisciplinary perspective that integrates AM, surface engineering and fatigue mechanics. By reframing surface integrity as a controlling design variable rather than a secondary outcome of processing, it offers a structured framework for predictive, performance-based surface engineering in AM metals.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Surface Treatment and Residual Stress · Additive Manufacturing and 3D Printing Technologies
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Yıldız Technical University Department of Mechanical Engineering, , Istanbul, , and Information Technologies Research and Application Center, Istanbul Ticaret University, Istanbul, Turkey
Yozgat Bozok University Akdağmadeni Vocational High School, , Yozgat,
Opole University of Technology Faculty of Mechanical Engineering, , Opole, , and Department of Machining, Assembly and Engineering Metrology, Faculty of Mechanical Engineering, VSB–Technical University of Ostrava, Ostrava, Czech Republic
Funding
European Union under the REFRESH – Research Excellence For Region Sustainability and High-tech Industries · Yildiz Technical University Scientific Research Projects Coordination Unit
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