Mechanical behaviour of additively manufactured metals

Zhu, Ting [Georgia Institute of Technology, Atlanta, GA (United States)] (ORCID:0000000186129689); Chen, Wen [University of Southern California, Los Angeles, CA (United States)] (ORCID:0000000320481107)

doi:10.1038/s41563-025-02459-5

DOE OSTI · 3013534

Mechanical behaviour of additively manufactured metals

Zhu, Ting [Georgia Institute of Technology, Atlanta, GA (United States)] (ORCID:0000000186129689)·Chen, Wen [University of Southern California, Los Angeles, CA (United States)] (ORCID:0000000320481107)

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Abstract

Additive manufacturing is reshaping the production of engineering components in diverse industries, such as the automotive, aerospace, defense, and biomedical sectors, by offering unprecedented design flexibility. The non-equilibrium processing conditions of additive manufacturing generate materials with unique microstructures and tailored mechanical properties that are often unattainable through conventional routes. This review focuses on recent advances in additively manufactured metals that demonstrate distinctive mechanical behaviors, including strength-ductility synergy, microstresses and gradient plasticity, fracture and fatigue resistance, and high-temperature creep performance. Here, we examine the mechanisms and micromechanical effects arising from the heterogeneous microstructures fabricated by additive manufacturing, to guide the design of a wide range of high-performance structural materials. Furthermore, we discuss critical research needs and emerging opportunities in process control, alloy design, advanced characterization, high-fidelity computational modeling, and machine learning aimed at achieving exceptional mechanical properties in additively manufactured metals.

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BibTeX RIS

Zhu, Ting [Georgia Institute of Technology, Atlanta, GA (United States)] (ORCID:0000000186129689), Chen, Wen [University of Southern California, Los Angeles, CA (United States)] (ORCID:0000000320481107). 2026-01-16. Mechanical behaviour of additively manufactured metals. https://doi.org/10.1038/s41563-025-02459-5

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