Review on laser directed energy deposited aluminum alloys
Source abstract
Abstract
Abstract Lightweight aluminum (Al) alloys have been widely used in frontier fields like aerospace and automotive industries, which attracts great interest in additive manufacturing (AM) to process high-value Al parts. As a mainstream AM technique, laser-directed energy deposition (LDED) shows good scalability to meet the requirements for large-format component manufacturing and repair. However, LDED Al alloys are highly challenging due to their inherent poor printability (e.g. low laser absorption, high oxidation sensitivity and cracking tendency). To further promote the development of LDED high-performance Al alloys, this review offers a deep understanding of the challenges and strategies to improve printability in LDED Al alloys. The porosity, cracking, distortion, inclusions, element evaporation and resultant inferior mechanical properties (worse than laser powder bed fusion) are the key challenges in LDED Al alloys. Processing parameter optimizations, in-situ alloy design, reinforcing particle addition and field assistance are the efficient approaches to improving the printability and performance of LDED Al alloys. The underlying correlations between processes, alloy innovation, characteristic microstructures, and achievable performances in LDED Al alloys are discussed. The benchmark mechanical properties and primary strengthening mechanism of LDED Al alloys are summarized. This review aims to provide a critical and in-depth evaluation of current progress in LDED Al alloys. Future opportunities and perspectives in LDED high-performance Al alloys are also outlined.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Additive Manufacturing and 3D Printing Technologies · Aluminum Alloy Microstructure Properties
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (100+)
Show source-provided references
1. Feature-based volumetric defect classification in metal additive manufacturing10.1038/s41467-022-34122-x ↗
2. Controlling process instability for defect lean metal additive manufacturing10.1038/s41467-022-28649-2 ↗
3. Additive manufacturing of micro-architected metals via hydrogel infusion10.1038/s41586-022-05433-2 ↗
4. Study of the intrinsic mechanisms of nickel additive for grain refinement and strength enhancement of laser aided additively manufactured Ti–6Al–4V10.1088/2631-7990/ac6b61 ↗
5. 3D Printing
6. Progress and perspectives in laser additive manufacturing of key aeroengine materials10.1016/j.ijmachtools.2021.103804 ↗
7. Nano-additive manufacturing of multilevel strengthened aluminum matrix composites10.1088/2631-7990/ac9ba2 ↗
8. An overview of laser-based multiple metallic material additive manufacturing: from macro- to micro-scales10.1088/2631-7990/abce04 ↗
9. Mechanical property and biological behaviour of additive manufactured TiNi functionally graded lattice structure10.1088/2631-7990/ac94fa ↗
10. Nanoparticle-enabled phase control for arc welding of unweldable aluminum alloy 707510.1038/s41467-018-07989-y ↗
11. Inhibiting weld cracking in high-strength aluminium alloys10.1038/s41467-022-33188-x ↗
12. Precipitation strengthening of aluminum alloys by room-temperature cyclic plasticity10.1126/science.aav7086 ↗
13. Porous metal implants: processing, properties, and challenges10.1088/2631-7990/acdd35 ↗
14. Feasibility and reliability of laser powder bed fused AlSi10Mg/wrought AA6061 hybrid aluminium alloy component10.1007/s40684-022-00456-6 ↗
15. Influence mechanism of process parameters on relative density, microstructure, and mechanical properties of low Sc-content Al-Mg-Sc-Zr alloy fabricated by selective laser melting10.1016/j.cjmeam.2022.100034 ↗
16. Development and applications of aluminum alloys for aerospace industry10.1016/j.jmrt.2023.09.274 ↗
17. HRL, nTopology, and Morf3D explore advanced design and materials with 7A77—the world’s strongest additive aluminum
18. Thales alenia space and poly-shape build Europe’s largest 3D printed satellite part
19. Recent progress on the additive manufacturing of aluminum alloys and aluminum matrix composites: microstructure, properties, and applications10.1016/j.ijmachtools.2023.104047 ↗
20. Effect of laser additive manufacturing on the microstructure and mechanical properties of TiB2 reinforced Al-Cu matrix composite10.1016/j.msea.2022.142950 ↗
21. A review on microstructures and properties of high entropy alloys manufactured by selective laser melting10.1088/2631-7990/ab9ead ↗
22. Wire arc additive manufacturing of Al-6Mg alloy using variable polarity cold metal transfer arc as power source10.1016/j.msea.2017.11.084 ↗
23. Opportunities and challenges in additive manufacturing of functionally graded metallic materials via powder-fed laser directed energy deposition: a review10.1016/j.jmatprotec.2021.117117 ↗
24. Influence of TiB2 volume fraction on SiCp/AlSi10Mg composites by LPBF: microstructure, mechanical, and physical properties10.1016/j.jmrt.2023.02.031 ↗
25. Effect of multiple thermal cycles on the microstructure evolution of GA151K alloy fabricated by laser-directed energy deposition10.1016/j.addma.2022.102957 ↗
26. Laser-based directed energy deposition (DED-LB) of advanced materials10.1016/j.msea.2022.142967 ↗
27. Strengthening and fracturing mechanisms of laser-directed energy deposited Al-7075 alloy10.1016/j.msea.2023.145433 ↗
28. Current research and industrial application of laser powder directed energy deposition10.1007/s00170-021-08596-w ↗
29. Laser aided additive manufacturing of spatially heterostructured steels10.1016/j.ijmachtools.2021.103817 ↗
30. Robust metal additive manufacturing process selection and development for aerospace components10.1007/s11665-022-06850-0 ↗
31. Laser-based directed energy deposition of novel Sc/Zr-modified Al-Mg alloys: columnar-to-equiaxed transition and aging hardening behavior10.1016/j.jmst.2020.08.003 ↗
32. Technical basis of using laser direct energy deposition as a high-throughput combinatorial method for DC-cast Al-Mn alloy development10.1016/j.matdes.2021.110290 ↗
33. Investigation of temperature distribution and solidification morphology in multilayered directed energy deposition of Al-0.5Sc-0.5Si alloy10.1016/j.ijheatmasstransfer.2021.122492 ↗
34. Mechanically strong, stiff, and yet ductile AlSi7Mg/graphene composites by laser metal deposition additive manufacturing10.1016/j.msea.2021.141749 ↗
35. Microstructure and mechanical properties of SiC reinforced AlSi10Mg composites fabricated by laser metal deposition10.1016/j.jmapro.2020.08.073 ↗
36. Improving the mechanical properties of Al-5Si-1Cu-Mg aluminum alloy produced by laser additive manufacturing with post-process heat treatments10.1016/j.msea.2018.08.074 ↗
37. The microstructure tailoring and property improving of directed energy deposited Al-Zn-Mg-Cu alloy modified with various Si and ZrO2 contents10.1016/j.matchar.2022.111896 ↗
38. Influence of heat treatment on microstructure evolution and mechanical properties of TiB2/Al 2024 composites fabricated by directed energy deposition10.1016/j.jmrt.2020.10.014 ↗
39. Directed energy deposition of Al 5xxx alloy using laser engineered net shaping (LENS®)10.1016/j.matdes.2020.108763 ↗
40. Challenges in additive manufacturing of high-strength aluminium alloys and current developments in hybrid additive manufacturing10.1016/j.ijlmm.2020.12.004 ↗
41. Enhanced printability and strength of unweldable AA2024-based nanocomposites fabricated by laser powder bed fusion via nano-TiC-induced grain refinement10.1016/j.msea.2022.144010 ↗
42. Enhanced strength and ductility in Al-Zn-Mg-Cu alloys fabricated by laser powder bed fusion using a synergistic grain-refining strategy10.1016/j.jmst.2021.12.078 ↗
43. Achieving excellent strength of the LPBF additively manufactured Al–Cu–Mg composite via in-situ mixing TiB2 and solution treatment10.1016/j.msea.2022.143531 ↗
44. Microstructure, mechanical properties and fatigue crack growth behavior of an Al-Zn-Mg-Cu-Si-Zr-Er alloy fabricated by laser powder bed fusion10.1016/j.ijfatigue.2023.107636 ↗
45. Microstructure characterization and mechanical properties of crack-free Al-Cu-Mg-Y alloy fabricated by laser powder bed fusion10.1016/j.addma.2022.103006 ↗
46. Microstructure, mechanical properties, aging behavior, and corrosion resistance of a laser powder bed fusion fabricated Al-Zn-Mg-Cu-Ta alloy10.1016/j.msea.2021.142364 ↗
47. Effects of powder reuse on the microstructure and mechanical behaviour of Al–Mg–Sc–Zr alloy processed by laser powder bed fusion (LPBF)10.1016/j.addma.2020.101625 ↗
48. Anisotropic response in corrosion behavior of laser powder bed fusion Al-Mn-Mg-Sc-Zr alloy10.1016/j.corsci.2022.110634 ↗
49. Review of high-strength aluminium alloys for additive manufacturing by laser powder bed fusion10.1016/j.matdes.2022.110779 ↗
50. 3D printing of Aluminium alloys: additive Manufacturing of Aluminium alloys using selective laser melting10.1016/j.pmatsci.2019.100578 ↗
51. A review of selective laser melting of aluminum alloys: processing, microstructure, property and developing trends10.1016/j.jmst.2018.09.004 ↗
52. Exploring the potential of FSW-ed Al–Zn–Mg–Cu-based composite reinforced by trace in-situ nanoparticles in manufacturing workpiece with customizable size and high mechanical performances10.1016/j.compositesb.2022.110425 ↗
53. Role of trace nanoparticles in establishing fully optimized microstructure configuration of cold-rolled Al alloy10.1016/j.matdes.2021.109743 ↗
54. Enhancing strength-ductility synergy and mechanisms of Al-based composites by size-tunable in-situ TiB2 particles with specific spatial distribution10.1016/j.compositesb.2021.108912 ↗
55. Innovation for forming aluminum alloy thin shells at ultra-low temperature by the dual enhancement effect10.1088/2631-7990/ac6b62 ↗
56. Grain refining in weld metal using short-pulsed laser ablation during CW laser welding of 2024-T3 aluminum alloy10.1088/2631-7990/ab563a ↗
57. The influence of laser directed energy deposition (DED) processing parameters for Al5083 studied by central composite design10.1016/j.jmrt.2022.02.042 ↗
58. Laser diode area melting for high speed additive manufacturing of metallic components10.1016/j.matdes.2016.12.095 ↗
59. Influence of aluminium powder aging on directed energy deposition10.1016/j.matdes.2022.110677 ↗
60. Influence of alloying elements on laser powder bed fusion processability of aluminum: a new insight into the oxidation tendency10.1016/j.addma.2021.102145 ↗
61. A review of laser powder bed fusion additive manufacturing of aluminium alloys: microstructure and properties10.1016/j.addma.2021.102155 ↗
62. Powder spreading and spreadability in the additive manufacturing of metallic materials: a critical review10.1016/j.jmatprotec.2022.117706 ↗
63. Prediction of lack of fusion porosity in selective laser melting based on melt pool monitoring data10.1016/j.addma.2018.11.015 ↗
64. The microstructure regulation and property enhancement of directed energy deposited Al-Zn-Mg-Cu-Si-Zr alloy with various Zr contents10.1016/j.matchemphys.2023.127318 ↗
65. Insight into solidification microstructure control by trace TiCN–TiB2 particles for yielding fine-tuned nanoprecipitates in a hypoeutectic Al–Si–Mg alloy10.1016/j.msea.2021.142093 ↗
66. Al–Cu alloy fabricated by novel laser-tungsten inert gas hybrid additive manufacturing10.1016/j.addma.2019.100954 ↗
67. Mechanical properties of AlSi10Mg alloy fabricated by laser melting deposition and improvements via heat treatment10.1016/j.ijleo.2018.10.112 ↗
68. Effect of processing parameters on solidification defects behavior of laser deposited AlSi10Mg alloy10.1016/j.vacuum.2019.06.042 ↗
69. 3D printing of high-strength aluminium alloys10.1038/nature23894 ↗
70. Control of second-phase particles in the Al-Mg-Mn alloy AA 508310.1016/j.jallcom.2016.08.070 ↗
71. Cracking criterion for high strength Al–Cu alloys fabricated by selective laser melting10.1016/j.addma.2020.101709 ↗
72. Synergistic optimization in solidification microstructure and mechanical performance of novel (TiC x N y − TiB2)p/Al nanocomposites: design, tuning and mechanism10.1016/j.compositesa.2022.106843 ↗
73. Ultrahigh-strength titanium gyroid scaffolds manufactured by selective laser melting (SLM) for bone implant applications10.1016/j.actamat.2018.08.005 ↗
74. Review on field assisted metal additive manufacturing10.1016/j.ijmachtools.2023.104032 ↗
75. Fast scanning calorimetry study of Al alloy powder for understanding microstructural development in laser powder bed fusion10.1016/j.matdes.2022.110830 ↗
76. Microstructure and mechanical properties of AlSi10Mg alloy built by laser powder bed fusion/direct energy deposition hybrid laser additive manufacturing10.1016/j.addma.2022.103160 ↗
77. In process monitoring of the thermal profile during solidification in laser directed energy deposition of aluminium10.1016/j.addlet.2022.100084 ↗
78. The microstructures and mechanical properties of Al-Zn-Mg-Cu-Si-Zr alloy: a comparison between directed energy deposition and laser powder bed fusion10.1016/j.matlet.2023.133959 ↗
79. The effect of build direction and heat treatment on atmospheric stress corrosion cracking of laser powder bed fusion 316L austenitic stainless steel10.1016/j.addma.2021.101902 ↗
80. Crystallographic orientation dependence of Charpy impact behaviours in stainless steel 316L fabricated by laser powder bed fusion10.1016/j.addma.2021.102104 ↗
81. The effects of laser irradiation on an aluminium powder stream in directed energy deposition10.1016/j.addma.2021.101968 ↗
82. Laser metal deposition of nickel coated Al 7050 alloy10.1016/j.jallcom.2017.05.171 ↗
83. Processing AlSi10Mg by selective laser melting: parameter optimisation and material characterisation10.1179/1743284714Y.0000000702 ↗
84. Microstructure and mechanical property considerations in additive manufacturing of aluminum alloys10.1557/mrs.2016.214 ↗
85. Characterization of the deposit-foaming of pure aluminum and Al-Mg-0.7Si alloys using directed energy deposition based on their metallurgical characteristics and compressive behaviors10.1016/j.addma.2022.103119 ↗
86. Porosity formation and gas bubble retention in laser metal deposition10.1007/s00339-009-5266-3 ↗
87. The effect of gravity and temperature gradients on precipitation in immiscible alloys10.1007/BF01115694 ↗
88. Wire-based laser directed energy deposition of AA7075: effect of process parameters on microstructure and mechanical properties10.1016/j.jmrt.2022.09.051 ↗
89. Some factors affecting porosity in directed energy deposition of AlMgScZr-alloys10.1016/j.optlastec.2021.107337 ↗
90. Functionally graded Al–Al3Ni in situ intermetallic composites: fabrication and microstructural characterization10.1016/j.jallcom.2006.11.181 ↗
91. Alumina and tricalcium phosphate added CoCr alloy for load-bearing implants10.1016/j.addma.2020.101553 ↗
92. A framework to link localized cooling and properties of directed energy deposition (DED)-processed Ti-6Al-4V10.1016/j.actamat.2017.04.027 ↗
93. Fatigue behavior and failure mechanisms of direct laser deposited Ti–6Al–4V10.1016/j.msea.2015.12.026 ↗
94. Correlation between porosity and processing parameters in TiAl6V4 produced by selective laser melting10.1016/j.matdes.2016.05.070 ↗
95. Selective laser melting of micron-sized niobium functionalized Al7075 alloy: element evaporation and grain refinement10.1016/j.msea.2022.142595 ↗
96. Microstructure and mechanical properties of laser DED produced crack-free Al 7075 alloy: effect of process parameters and heat treatment10.1016/j.msea.2022.144075 ↗
97. Additive manufacturing of metallic components—process, structure and properties10.1016/j.pmatsci.2017.10.001 ↗
98. The metallurgy and processing science of metal additive manufacturing10.1080/09506608.2015.1116649 ↗
99. Directed energy deposition (DED) additive manufacturing: physical characteristics, defects, challenges and applications10.1016/j.mattod.2021.03.020 ↗
100. Processing window for laser metal deposition of Al 7075 powder with minimized defects10.1016/j.jmapro.2021.02.031 ↗