Recent Advances in Abrasive Jet Machining: A Review of Materials, Techniques, and Industrial Applications

This literature review presents a comprehensive analysis of the advancements in Abrasive Jet Machining (AJM) for machining applications over the past decade (2015–2025). AJM has evolved from a coarse material removal method to a precision manufacturing process, driven by innovations in abrasive materials, nozzle designs, jet control strategies, and hybrid processing techniques. This review categorizes and synthesizes findings from peer-reviewed studies published in high-impact journals, focusing on developments in nano-structured and composite abrasives, functionally graded nozzle materials, and advanced carrier media. Processing advancements such as optimized nozzle geometries, pulsed and submerged jet techniques, and AI-driven control frameworks are critically examined. AJM's application spectrum is analyzed across aerospace, biomedical, microfabrication, and electronic domains, emphasizing its unique capabilities for machining hard, brittle, and thermally sensitive materials. Comparative assessments highlight AJM's advantages in material versatility, surface integrity, and sustainability over conventional and thermal-based machining techniques. The review also identifies existing challenges—such as nozzle wear, process standardization, and abrasive waste—and outlines future directions including smart AJM systems, green abrasives, and integration with additive manufacturing post-processing. Collectively, the findings position AJM as a versatile and strategic technology for precision, clean, and adaptive manufacturing.