Composite forming system combining additive manufacturing and forging and methods for same

An additive manufacturing system, comprising:

• a material conveyor configured to feed a material;
• an energy source configured to direct an energy beam toward the material to fuse at least a portion of the material to form a solidified part;
• a microforging device movable along with the material conveyor for forging the solidified part, wherein the microforging device comprises a first forging hammer configured to impact the solidified part to generate a first deformation and a second forging hammer configured to impact the solidified part to generate a second deformation greater than the first deformation, and wherein the microforging device is movable relative to the material conveyor between a hot forging position and a cold forging position farther away from the material conveyor than the hot forging position;
• a connector, wherein the material conveyor and the microforging device are each attached to the connector, and the microforging device is movable along the connector relative to the material conveyor between the hot forging position and the cold forging position;
• a control device that controls a relative position of the microforging device and a motion parameter of the microforging device, wherein the motion parameter comprises a first vibration frequency for the first forging hammer and a second vibration frequency for the second forging hammer;
• and
• a polishing device synchronously movable with the microforging device that can polish the solidified part after the microforging device forges the solidified part by abrading or cutting a surface of the solidified part by physical contact between the surface and the polishing device, wherein the polishing device is attached to the connector.