Products made from additive manufacturing processes have attracted great attention in engineering, health care, and society at large. However, there is little knowledge about the failure of additively manufactured alloys, in particular, corrosion and wear seen in most engineering applications. The haphazard and inefficient usage of such alloys raised concerns about safety, compatibility, reliability, cost, and consumer satisfaction. To address those concerns, we studied the mechanisms of the most common failure modes, corrosion and wear, of alloys fabricated through additive manufacturing based on published literature. It was found that the processing conditions have profound influence on microstructure and thus corrosion and wear resistance of alloys. Because of the layered structure, the initiation and growth of both corrosion and wear exhibited anisotropic behavior. The insights from this review could be used as a reference of the state-of-the art and to help in the development of future additively manufactured alloys with improved corrosion and wear properties.

Vitrimers, although categorized as thermosetting polymers, differ from traditional ones in that their thermally induced crosslinks undergo reconfiguration through covalent bond exchanges in response to thermal stimuli. Exchangeable bonds present significant and distinctive advantages for thermoset‐based aerospace composites, facilitating capabilities such as self‐repair and crack arrest through molecular bridging. In this work, the self‐healing behavior of four different blends of Aromatic Thermosetting Copolyester (ATSP) coatings, which are high‐performance vitrimer polymers, is tested by introducing micro‐scratches on the surface and healing them at higher temperatures. In three blends, the scratches are completely healed indicating complete repair. This property of the ATSP coatings can be useful in extreme conditions where micro‐cracks lead to failure. The healing ability of the vitrimers is discussed in terms of their mechanical properties and morphological parameters such as branch density.

In this research, a novel flash heating coating application technique was utilized to create Ni-SiC coatings on carbon steel substrates with SiC contents much higher than is achievable using certain conventional coating techniques. Hardness profiles showed that the coatings improved the substrate by as much as 121%, without affecting the substrate. Tribotests showed that the wear performance was improved by as much as 4.7$\times$ in terms of the wear rate (mm³/N·m) for the same coating when using an Al₂O₃ counterpart. Pure SiC coatings as a reference were also fabricated. However, the SiC coatings experienced elemental diffusion of Fe from the carbon steel substrate into the coating during fabrication. This occurred due to the increased heat input required for pure SiC to fuse to the substrate compared to the Ni-SiC coatings and resulted in decreased tribological performance. Diffusion of Fe into the coating weakened the coating’s hardness and reduced the resistance to wear. It was concluded that ceramic–metallic composite coatings can successfully be fabricated utilizing this novel flash heating technique to improve the wear resistance of ceramic counterparts.