Advancements in Hybrid Abrasive Flow Finishing: Fundamentals, Technological Developments, and Industrial Applications in Precision Manufacturing

ABSTRACT: Hybrid-Based Abrasive Flow Finishing (HAFF) represents a significant evolution in precision manufacturing, particularly in addressing the inherent limitations of traditional finishing techniques when dealing with complex geometries and challenging materials. HAFF achieves remarkable precision in managing particle motion by blending state-of-the-art energy inputs and mechanical reinforcements, including sonic vibrations, electromagnetic influences, and beam-guided supports, which accelerate the pace of material extraction and elevate the overall finish of surfaces. This paper comprehensively reviews various HAFF approaches, including energy-assisted methods (e.g., electrochemical, ultrasonic, and laser), force-assisted techniques (e.g., magnetic, hydrodynamic, and vibration), and hybrid energy-force integrated systems. Recent advancements, such as cryogenic-assisted, rotational-assisted, and magnetorheological-assisted AFF, are also discussed in this review. Recent studies from 2023 to 2025 highlight improvements in material removal rates of up to 80% and reductions in surface roughness of over 90% across various HAFF variants, underscoring the timeliness of these developments. Incorporating diverse power sources and mechanical aids into HAFF allows for exact oversight of particle interactions, speeding up the removal of excess material, refining the exterior finish, and broadening its utility across detailed designs and tough-to-process substances. Despite significant progress, challenges persist in scaling HAFF processes for industrial applications, improving cost efficiency, and implementing effective real-time monitoring systems. The future trajectory of HAFF research will focus on the development of innovative abrasive media, advanced automation technologies, artificial Intelligence techniques, and sustainable manufacturing practices. This study examines all existing HAFF technology solutions and evaluates product applications for aerospace, automotive, medical equipment, and micro-manufactured devices. The discussion highlights the industries that require more advanced technological investigations.