Advanced Manufacturing Processes: Powder Metallurgy, Joining, Surface Finishing, and Machining

Abstract

The increasing demand for lightweight, high-strength, and cost-efficient components has intensified the need for advanced manufacturing processes, yet persistent limitations across powder metallurgy, joining, surface finishing, and machining continue to hinder optimal product performance and industrial scalability. This systematic review followed PRISMA guidelines, searching major databases using relevant manufacturing keywords. From 1,287 records, duplicates and irrelevant studies were removed. After full-text eligibility assessment, 49 peer-reviewed articles focusing on powder metallurgy, machining, joining, and surface finishing were included to provide comprehensive evidence on advanced manufacturing processes. Powder metallurgy (PM) demonstrates strong sustainability advantages through high material utilization, while optimized sintering and mechanical alloying significantly enhance hardness, density, and fatigue performance. Advanced joining methods—laser welding, friction stir welding, and hybrid techniques—produce high-strength, low-distortion joints suited for complex or dissimilar materials. Surface finishing technologies, including corrosion-resistant coatings and nanocoatings, substantially improve wear, corrosion resistance, and service life. Machining advances such as high-speed machining, EDM, and laser micromachining increase precision, productivity, and suitability for hard or lightweight materials. Integrated use of PM, machining, joining, and finishing enhances performance, though adoption faces barriers such as high investment, skill shortages, and system-integration challenges.