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Armington Professorship"},{"name":"Distinguished University Professorship"},{"name":"Swanger Fellowship"}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Materials"],"abstract":"<jats:p>Metal additive manufacturing (AM) enables near-net-shape fabrication of complex components, but process-induced defects and heterogeneities continue to limit performance and broader adoption. This review examines ex-situ and in-situ hybrid processing across multiple AM processes and alloy systems, including heat treatment, deformation-based processing, hot isostatic pressing, machining, friction stir processing, ultrasonic and magnetic-field assistance, alloying, stirring, and surface preparation. Ex-situ routes modify the completed build through bulk densification, homogenization, phase control, and surface improvement, whereas in-situ routes modify defects, microstructure, residual stress, and phase evolution during fabrication by interacting with the liquid melt pool, viscoplastic material, or solidified layer(s). The in-situ hybrid processing literature is dominated by wire-based directed energy deposition (DED) because its open architecture facilitates secondary-tool integration. Deformation-based methods were the most common and frequently promoted pore closure, recrystallization, texture modification, residual-stress redistribution, and improved mechanical performance. Hybrid processing was most effective when integrated to target the dominant material-specific limitation. Aluminum alloys benefited primarily from porosity control, stainless steels from grain and texture modification, titanium alloys from prior-\u03b2 and \u03b1\/\u03b2 morphology control, nickel-based superalloys from segregation and Laves-phase mitigation, and steels from control of transformation microstructures. This material-state-aware framework may also extend to polymers and composites.<\/jats:p>","DOI":"10.3390\/ma19183927","type":"journal-article","created":{"date-parts":[[2026,9,15]],"date-time":"2026-09-15T18:23:53Z","timestamp":1789496633000},"page":"3927","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Ex-Situ and In-Situ Hybrid Processing Opportunities in Metal Additive Manufacturing"],"prefix":"10.3390","volume":"19","author":[{"ORCID":"https:\/\/orcid.org\/0000-0002-8699-9235","authenticated-orcid":false,"given":"Vishnu","family":"Ramasamy","sequence":"first","affiliation":[{"name":"Department of Materials Science and Engineering, Case Western Reserve University, Cleveland, OH 44106, USA"},{"name":"Department of Materials Science and Engineering, The Ohio State University, Columbus, OH 43210, USA"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"given":"Mingchen","family":"Qu","sequence":"additional","affiliation":[{"name":"Department of Materials Science and Engineering, Case Western Reserve University, Cleveland, OH 44106, USA"}],"role":[{"vocabulary":"crossref","role":"author"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-3389-2637","authenticated-orcid":false,"given":"John J.","family":"Lewandowski","sequence":"additional","affiliation":[{"name":"Department of Materials Science and Engineering, Case Western Reserve University, Cleveland, OH 44106, USA"}],"role":[{"vocabulary":"crossref","role":"author"}]}],"member":"1968","published-online":{"date-parts":[[2026,9,15]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","first-page":"151","DOI":"10.1146\/annurev-matsci-070115-032024","article-title":"Metal Additive Manufacturing: A Review of Mechanical Properties","volume":"46","author":"Lewandowski","year":"2016","journal-title":"Annu. 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