Recent Trends and Future Scope of Ultrasonic Machining in Aerospace Applications

Ultrasonic machining (USM) and its derivative processes—rotary ultrasonic machining (RUM), ultrasonic vibration-assisted machining (UVAM), and multi-dimensional (elliptical) vibration machining—have become important enabling technologies for the manufacture of aerospace components made from difficult-to-cut materials such as titanium alloys, nickel-based superalloys, carbon-fiber-reinforced polymers, and particle- and ceramic-matrix composites. This paper reviews recent trends in ultrasonic machining research relevant to aerospace applications, covering process fundamentals, material-specific developments, hybrid energy-field-assisted variants, and reported improvements in cutting force, tool wear, delamination, and surface integrity. Persistent challenges relating to material removal rate, tool and horn design, process modeling, and shop-floor integration are discussed, followed by an outlook on multi-physics modeling, sensor-integrated adaptive control, hybrid manufacturing, and sustainability-driven process development that are expected to shape the future scope of ultrasonic machining in the aerospace sector.