Jingwei Sun

Difficult-to-machine metallic materials, distinguished by their high strength, hardness, and corrosion resistance, are indispensable in critical fields such as aerospace and defense. However, these very attributes also pose substantial challenges to conventional machining technologies. As an advanced external-field machining technology, electropulsing-assisted machining provides unique advantages in enhancing plastic deformability, refining microstructures, improving machining precision, and boosting efficiency. This paper provides a comprehensive review of the fundamental mechanisms governing the interaction between electropulsing and metallic materials, synthesizes the latest advances in electropulsing-assisted machining methods, and highlights unresolved challenges alongside promising future directions. By bridging the gap between material science and advanced manufacturing, this review aims to stimulate innovation and accelerate the adoption of electropulsing-assisted machining in the processing of next-generation high-performance metallic materials.