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<p>Aluminium (Al) alloys are extensively used in critical industries such as aerospace, automotive, and medical, owing to their excellent mechanical properties, low density, and corrosion resistance. However, traditional manufacturing methods like casting and machining face limitations when manufacturing complex components and structures. Additive manufacturing (AM), particularly laser powder bed fusion (LPBF) and laser directed energy deposition (LDED), offers a great potential for producing intricate Al alloy components with improved performance characteristics. The present review presents a comprehensive overview of recent advancements in the processing of Al alloys using LPBF and LDED. Review begins with a concise description of AM technologies, outlining their benefits and limitations, and then focusses on the fabrication of Al alloys, highlighting the critical challenge of achieving defect-free components. Various Al alloys, including Al2024, AlSi10Mg, AlSi12, Al6061, and Al7075, are discussed in terms of their processing using these techniques and their characterization. The review highlights the defect related challenges in fabricating Al alloys through LPBF and LDED and discusses strategies to minimize or eliminate them. It further examines the resulting microstructural and mechanical properties, including porosity, hardness, tensile strength, elongation and fatigue strength. Lastly, the review elucidates future research directions and identifies key research gaps in Al alloy fabrication employing additive manufacturing processes.</p>

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Overview of Laser Powder Bed Fusion and Laser Directed Energy Deposition of Aluminium Alloys: Process, Defects, Microstructure, and Mechanical Properties

  • 期刊论文

  • 发表日期：

    2025年12月5日

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  • Sai Kumar Balla,
  • Manjaiah Mallaiah,
  • Selvaraj Nagamuthu,
  • Raj Das

摘要

Aluminium (Al) alloys are extensively used in critical industries such as aerospace, automotive, and medical, owing to their excellent mechanical properties, low density, and corrosion resistance. However, traditional manufacturing methods like casting and machining face limitations when manufacturing complex components and structures. Additive manufacturing (AM), particularly laser powder bed fusion (LPBF) and laser directed energy deposition (LDED), offers a great potential for producing intricate Al alloy components with improved performance characteristics. The present review presents a comprehensive overview of recent advancements in the processing of Al alloys using LPBF and LDED. Review begins with a concise description of AM technologies, outlining their benefits and limitations, and then focusses on the fabrication of Al alloys, highlighting the critical challenge of achieving defect-free components. Various Al alloys, including Al2024, AlSi10Mg, AlSi12, Al6061, and Al7075, are discussed in terms of their processing using these techniques and their characterization. The review highlights the defect related challenges in fabricating Al alloys through LPBF and LDED and discusses strategies to minimize or eliminate them. It further examines the resulting microstructural and mechanical properties, including porosity, hardness, tensile strength, elongation and fatigue strength. Lastly, the review elucidates future research directions and identifies key research gaps in Al alloy fabrication employing additive manufacturing processes.