Metal Forming and Additive Manufacturing Processes for High-Performance Materials, Components, Structures, and Applications

The relentless pursuit of lightweight, high-performance, and complex-structure components in aerospace, automotive, and energy sectors pushes manufacturing to its limits. Conventional metal forming processes offer unmatched efficiency and microstructural control for integration of precise shaping and property control, but face constraints in complex geometric design and tooling cost. Conversely, additive manufacturing (AM) enables unprecedented design complexity and customization, yet challenges remain in surface quality, production rate, and microstructure regulation. This presents both a divide and a tremendous opportunity for synergy. This research topic aims to bridge these domains, exploring their convergence and individual advances. We seek contributions that address these fields, from advanced processing technologies and innovative alloy design to the modeling of microstructure and performance, for manufacturing next-generation metal-based components and structures. The integration of hybrid manufacturing and data-driven methodologies also stands as a frontier in this evolution.The primary goal of this Research Topic is to curate a comprehensive collection of cutting-edge research and critical reviews that illuminate the frontier of manufacturing high-performance metallic systems. We aim to move beyond viewing metal forming and additive manufacturing (AM) as competing alternatives. Specifically, we seek to achieve the following objectives: (1) Encourage innovation in individual processes, showcasing advances in advanced metal forming techniques, novel solid-state and fusion-based AM processes, special energy-assisted methods that enhance material formability and properties, and hybrid manufacturing, where metal forming and AM are strategically combined. (2) Promote the development and processing of advanced materials, including high-strength alloys, high-entropy alloys, metal-matrix composites, and architectured metamaterials, focusing on microstructure-property relationships. (3) Highlight the critical role of modeling and simulations, from fundamental constitutive and crystal plasticity models, to multiscale modeling, and emerging data-driven technologies techniques, including machine learning, artificial intelligence (AI), and digital twins, for a new generation of process prediction, design, and optimization. This topic will serve as a foundational reference, identifying key challenges, synergies, and future directions for manufacturing the high-integrity, multifunctional metallic components.This Research Topic is seeking manuscripts that deal with the following:-Advanced metal forming technologies, including forging, tube and sheet forming, spinning, and rolling-Metal additive manufacturing, including solid-state and fusion-based processes-Energy-assisted processing, such as electrically assisted, electromagnetic, ultrasonic, cryogenic, and laser-assisted forming-Hybrid manufacturing combining metal forming and additive manufacturing-Metals, metal-matrix composites, and advanced alloy design, including high-strength, high-entropy, and multi-principal element alloys-Complex component design, structural topology optimization, and processing-Multifunctional metallic lattice metamaterials-Mechanical properties, microstructure characterization and control, and damage, fatigue, and fracture behavior-Multiphysics and multiscale modeling, including finite element analysis and constitutive modeling-Crystal plasticity, grain boundary, and microstructure evolution modeling-Data-driven methods, including machine learning, AI, and digital twins Topic editors: Hongrui Zhang, Xinxin Sun, Dachuan Shi Source: https://www.frontiersin.org/research-topics/78649/metal-forming-and-additive-manufacturing-processes-for-high-performance-materials-components-structures-and-applications