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<p>Laser-based metal additive manufacturing process have attracted global attention across various manufacturing industries owing to their rapid production rate, design flexibility and its ability to repair existing components. Laser powder-directed energy deposition (LP-DED) is widely used for its high deposition rate and improved dimensional precision. The scope of this review article lies in the application area of LP-DED, majorly focused on Inconel and its alloys with emphasis on process-control and approaches to minimise material waste. It also addresses the cause–effect mitigation strategies to reduce defects associated with LP-DED processing of Inconel alloys, such as porosity, cracking, uneven surface roughness, and residual stresses in fabricated components, and directly relates these to the governing processing conditions. It also presents the current state of the LP-DED technology, identifies key challenges, and provides guidelines for improving microstructural, mechanical, and geometrical characteristics. Furthermore, this review recommends future research directions to address existing gaps through systematic study of peer-reviewed, open-access literatures on LP-DED processing of Inconel alloys focusing on improving process reliability, establishing robust process–structure–property relationships and enhancing component quality and its performance.</p>

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A Comprehensive Review of Current Status, Challenges, and Applications of Laser Powder Directed Energy Deposition (LP-DED) in Metal Additive Manufacturing Process for Inconel and Its Alloys

  • 期刊论文

  • 发表日期：

    2026年4月30日

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  • Sukumar Chundi,
  • Chandan Kumar,
  • Sujit Das

摘要

Laser-based metal additive manufacturing process have attracted global attention across various manufacturing industries owing to their rapid production rate, design flexibility and its ability to repair existing components. Laser powder-directed energy deposition (LP-DED) is widely used for its high deposition rate and improved dimensional precision. The scope of this review article lies in the application area of LP-DED, majorly focused on Inconel and its alloys with emphasis on process-control and approaches to minimise material waste. It also addresses the cause–effect mitigation strategies to reduce defects associated with LP-DED processing of Inconel alloys, such as porosity, cracking, uneven surface roughness, and residual stresses in fabricated components, and directly relates these to the governing processing conditions. It also presents the current state of the LP-DED technology, identifies key challenges, and provides guidelines for improving microstructural, mechanical, and geometrical characteristics. Furthermore, this review recommends future research directions to address existing gaps through systematic study of peer-reviewed, open-access literatures on LP-DED processing of Inconel alloys focusing on improving process reliability, establishing robust process–structure–property relationships and enhancing component quality and its performance.