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<p>Internal flow channels fabricated by additive manufacturing and precision casting are widely used in aerospace, hydraulic, medical, and heat transfer systems, where surface integrity critically affects flow efficiency and service reliability. However, as-built channels typically suffer from high roughness and various manufacturing-induced defects, making post-processing an essential step for performance enhancement. This paper presents a systematic review of recent advances in internal flow channel finishing technologies, including electrochemical/chemical polishing (ECP/CP), abrasive flow machining (AFM), abrasive fluid jet polishing (AFJ), magnetic abrasive finishing (MAF), composite polishing strategies, and emerging hybrid methods such as HydroFlex. The fundamental mechanisms, process characteristics, and applicability of each technique are critically analyzed. ECP/CP provides high material removal efficiency but is limited by electrolyte management and cathode design complexity. AFM and AFJ offer flexible access to internal geometries but suffer from flow instability, abrasive control challenges, and equipment cost issues. MAF demonstrates strong adaptability to complex structures and environmentally friendly processing but is constrained by magnetic field penetration and geometric accessibility. To overcome the limitations of single processes, composite and field-assisted techniques have been developed to enhance material removal uniformity and process stability. Emerging methods further integrate mechanical, fluidic, and magnetic interactions to improve adaptability to complex internal topologies. Finally, current challenges and future research directions are discussed, highlighting the development trends toward intelligent process control, multi-field coupling, sustainable manufacturing, and high-precision adaptive polishing for complex internal channels.</p>

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Post-processing of internal flow channels: A review

  • 期刊论文

  • 发表日期：

    2026年6月27日

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  • Hao Li,
  • Yujing Sun,
  • Guosheng Su,
  • Jin Du,
  • Binxun Li,
  • Peirong Zhang,
  • Yan Xia,
  • Mingdong Yi

摘要

Internal flow channels fabricated by additive manufacturing and precision casting are widely used in aerospace, hydraulic, medical, and heat transfer systems, where surface integrity critically affects flow efficiency and service reliability. However, as-built channels typically suffer from high roughness and various manufacturing-induced defects, making post-processing an essential step for performance enhancement. This paper presents a systematic review of recent advances in internal flow channel finishing technologies, including electrochemical/chemical polishing (ECP/CP), abrasive flow machining (AFM), abrasive fluid jet polishing (AFJ), magnetic abrasive finishing (MAF), composite polishing strategies, and emerging hybrid methods such as HydroFlex. The fundamental mechanisms, process characteristics, and applicability of each technique are critically analyzed. ECP/CP provides high material removal efficiency but is limited by electrolyte management and cathode design complexity. AFM and AFJ offer flexible access to internal geometries but suffer from flow instability, abrasive control challenges, and equipment cost issues. MAF demonstrates strong adaptability to complex structures and environmentally friendly processing but is constrained by magnetic field penetration and geometric accessibility. To overcome the limitations of single processes, composite and field-assisted techniques have been developed to enhance material removal uniformity and process stability. Emerging methods further integrate mechanical, fluidic, and magnetic interactions to improve adaptability to complex internal topologies. Finally, current challenges and future research directions are discussed, highlighting the development trends toward intelligent process control, multi-field coupling, sustainable manufacturing, and high-precision adaptive polishing for complex internal channels.