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Open research questions in Additive Manufacturing Materials and Processes

202 unresolved questions extracted from the limitations and future-work sections of 609 Additive Manufacturing Materials and Processes papers in our library. Each links back to the study that raised it.

What the literature leaves open

  • The need for precise deposition behavior prediction in advanced additive manufacturing. The limitations of traditional machine learning techniques in modeling complex nonlinear relationships.

    Explainable Ensemble Machine Learning for Predicting Deposition Characteristics in Advanced Additive Manufacturing · 2026 · DOI

  • Further research is needed to investigate the effects of other factors on material waste and part quality in WAAM. Research is needed to develop more advanced models that can predict material waste and part quality in WAAM. Studies should be conducted to apply the optimized parameters to other WAAM applications.

    Optimization of process parameters for wire arc additive manufacturing for repair-based applications using response surface methodology · 2026 · DOI

  • Investigating the effects of different heat treatment sequences on other materials, - Studying the impact of heat treatment on residual stress fields, - Examining the relationship between microstructure and mechanical properties in more detail

    Effects of Different Post-Processing Heat Treatment Sequences on the Mechanical Properties of AISI 316L Processed Through Laser-Directed Energy Deposition Additive Manufacturing · 2026 · DOI

  • The paper identifies a research gap in the understanding of the microstructure and mechanical properties of Ni superalloy fabricated by different AM processes. The study aims to address the gap by investigating the differences in microstructure and properties between L-DED and L-PBF processes. The paper also aims to optimize the microstructural characteristics and mechanical properties of Ni superalloy components produced by AM.

    Microstructure and mechanical properties of Ni superalloy fabricated by laser directed energy deposition (L-DED) versus laser powder bed fusion (L-PBF) · 2026 · DOI

  • The paper identifies the challenge of joining P92 and AISI 304L steels due to their different properties. The study highlights the difficulty of achieving sound fusion and avoiding microstructural defects. The paper mentions the need for careful selection of filler metals and welding parameters.

    Characterization of GMAW processed AISI 304L-P92 dissimilar steel joints: microstructure-property correlation · 2026 · DOI

  • Investigation of other filler metals and welding processes, - Study of the long-term properties of the welds, - Examination of the effect of welding parameters on the microstructure and properties of the welds

    Characterization of GMAW processed AISI 304L-P92 dissimilar steel joints: microstructure-property correlation · 2026 · DOI

  • The paper identifies a gap in the understanding of the corrosion behavior of Al5254 alloy with tantalum addition processed by powder bed fusion-laser beam. The study highlights the need for further research on the effects of tantalum addition on the alloy's chemical composition and corrosion resistance.

    Corrosion behaviour of Al5254 alloy with tantalum addition processed by powder bed fusion–laser beam · 2026 · DOI

  • The gap lies in the analysis of the microstructure-dependent properties of Ti6Al4V produced via different AM techniques. The influence of HIP on the densification and microstructural transformation in terms of mechanical properties is not well understood. The anisotropy of the mechanical properties requires further investigation.

    Influence of hot isostatic pressing on the microstructural and mechanical properties of Ti6Al4V produced via additive methods: laser powder bed fusion and cold spraying · 2026 · DOI

  • Further study on the effect of TiC particles on the microstructure formation and wear performance of Inconel 718. Investigation of the temperature field characteristics during the SAM process of Inconel 718 and TiC/Inconel 718 composite. Analysis of the variation of the maximum temperature of the molten pool during the forming process.

    Effect of TiC particles on the microstructure formation and wear performance of Inconel 718 fabricated by selective arc melting · 2026 · DOI

  • The paper identifies a research gap in the understanding of the effect of TiC particles on the microstructure formation and wear performance of Inconel 718. It also highlights the need for improving the wear performance of Inconel 718 using metal additive manufacturing techniques.

    Effect of TiC particles on the microstructure formation and wear performance of Inconel 718 fabricated by selective arc melting · 2026 · DOI

  • High surface pressures and elevated temperatures in die forging processes. Limited wear resistance of conventional H11 tool steel. The need for a comprehensive evaluation of WAAM as a repair and cladding solution for hot forging tools.

    WAAM-based repair cladding for forging tools: a comprehensive study of wear in laboratory and industrial conditions · 2026 · DOI

  • The gap in the durability of hot forging tools due to challenging working conditions. The lack of a comprehensive evaluation of WAAM as a repair and cladding solution for hot forging tools. The need for a study that demonstrates the mechanical properties and wear resistance of WAAM-fabricated tool steel.

    WAAM-based repair cladding for forging tools: a comprehensive study of wear in laboratory and industrial conditions · 2026 · DOI

  • High capital acquisition costs, - Stringent safety protocols for handling hazardous reactive powders, - Significant post-processing to mitigate thermal stresses, - Limited by challenges related to porosity, anisotropic shrinkage, and suboptimal interlayer bonding

    Enhancing microstructural and mechanical properties of 316L stainless steel through Material Extrusion (MEX) optimization · 2026 · DOI

  • Development of alternative manufacturing routes, - Optimization of printing parameters for other materials, - Investigation of the 'shell effect' in other additive manufacturing processes

    Enhancing microstructural and mechanical properties of 316L stainless steel through Material Extrusion (MEX) optimization · 2026 · DOI

  • The paper does not explicitly state a research gap, but it investigates the effects of boron doping on the microstructure and properties of Ni-based superalloy laser cladding layers. The study aims to improve the corrosion resistance and mechanical strength of these layers.

    Microstructure, hardness and corrosion resistance of B-doped Ni-based superalloy laser cladding layers · 2026 · DOI

  • further study on the effect of grain size on crack propagation, - investigation of the influence of stress ratio on fatigue crack growth in SS316L, - research on tailoring microstructure to enhance fatigue resistance

    Anisotropic fatigue crack growth in selective laser melted SS316L: integrated experimental and molecular dynamics investigation · 2026 · DOI

  • The anisotropic nature of additive manufacturing affects the mechanical properties of the material, but the underlying mechanisms are not well understood. There is a need for a comprehensive understanding of fatigue crack growth behavior in SLM-produced SS316L. The current study aims to address this gap by providing a qualitative understanding of fatigue crack growth in SLM-produced SS316L.

    Anisotropic fatigue crack growth in selective laser melted SS316L: integrated experimental and molecular dynamics investigation · 2026 · DOI

  • The paper identifies challenges in characterising the properties of Al-Ta composite powders, particularly in terms of particle morphology, size distribution, and structural integrity. It highlights the need for non-destructive techniques such as XCT to evaluate the internal structure of additively manufactured components.

    Multi-scale imaging of additively manufactured Al–Ta composites · 2026 · DOI

  • Investigating how mixture preparation and mixture proportions influence internal structure, - Concentrating on the effect of Ta particle morphology and dispersion on processed material

    Multi-scale imaging of additively manufactured Al–Ta composites · 2026 · DOI

  • Further research is needed to investigate the effects of other alloying elements on the microstructure and properties of GH4169 alloy. The study of the relationship between the microstructure and properties of GH4169 alloy at different temperatures is suggested. Research on the optimization of the SLM process parameters for GH4169 alloy is recommended.

    Effect of Minor P and C Regulation on Microstructure Evolution and High-Temperature Properties of Selective Laser Melted GH4169 Superalloy · 2026 · DOI

  • The effects of minor P and C regulation on microstructure evolution and high-temperature properties of SLM-fabricated GH4169 superalloy are not well understood. There is a lack of systematic studies on the impact of P and C variations on the properties of GH4169 superalloy fabricated by SLM.

    Effect of Minor P and C Regulation on Microstructure Evolution and High-Temperature Properties of Selective Laser Melted GH4169 Superalloy · 2026 · DOI

  • Further investigation of the effects of TIG pre-joining on WAAM hollow shafts, - Study of the long-term performance of TIG pre-joined WAAM hollow shafts, - Optimization of WAAM parameters for improved fatigue life

    Comparative study of the rotating bending fatigue performance of wire arc additively manufactured hollow shafts with and without TIG pre-joining · 2026 · DOI

  • The lack of understanding of the effect of TIG pre-joining on the rotating bending fatigue performance of WAAM-fabricated hollow shafts. The need to identify the optimal WAAM process parameters for maximizing fatigue life. The limited knowledge on the comparison of fatigue life between WAAM-fabricated hollow shafts with and without TIG pre-joining.

    Comparative study of the rotating bending fatigue performance of wire arc additively manufactured hollow shafts with and without TIG pre-joining · 2026 · DOI

  • The study focuses on a specific alloy (Inconel 725) and its behavior during heat treatment, - The sample size is limited to the sputtered coatings deposited using a 7.62 cm diameter Inconel 725 planar target, - The study does not explore the effects of other variables such as different substrate materials or deposition parameters

    Phase nucleation, coarsening and evolution pathways of a sputtered nanostructured Inconel 725 alloy during heat treatment · 2026 · DOI

  • Investigating the effects of twin boundaries on phase nucleation and phase evolution during thermal treatments, - Exploring the behavior of other alloys with similar nanotwinned structures, - Studying the mechanical properties of the alloy under different heat treatment conditions

    Phase nucleation, coarsening and evolution pathways of a sputtered nanostructured Inconel 725 alloy during heat treatment · 2026 · DOI

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202 open questions have been extracted from the limitations and future-work passages of 609 Additive Manufacturing Materials and Processes papers in our library. Each one below links back to the study that raised it, so you can read the original claim in context.

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