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<p>This review comprehensively examines recent advancements in laser additive manufacturing (LAM), focusing on its fundamental processes, microstructural evolution, and performance optimization strategies. The study outlines the essential physical mechanisms underlying laser–material interactions, including rapid solidification and non-equilibrium phase transformations, and discusses how process parameters influence the dynamic behavior of the melt pool and the resulting microstructure. Additionally, innovative techniques for defect control and quality enhancement—such as real-time multi-modal monitoring, in-situ diagnostics, and post-processing repair methods—are critically evaluated. The integration of multidisciplinary approaches, including digital twin technology, machine learning-based optimization, and advanced modeling techniques, is highlighted as a key driver for bridging the gap between laboratory research and industrial-scale production. Future research directions are identified in multi-material fabrication, intelligent closed-loop control, and sustainable manufacturing, paving the way for the next generation of high-performance, low-carbon, and net-zero emission manufacturing systems.</p> Graphical Abstract <p></p>

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Research Progress on the Multi-Physics Coupling Mechanisms of the Molten Pool in Laser Additive Manufacturing and Cross-Scale Performance Regulation

  • 期刊论文

  • 发表日期：

    2025年10月9日

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  • Hao Yang,
  • Zhongsheng Zhai

摘要

This review comprehensively examines recent advancements in laser additive manufacturing (LAM), focusing on its fundamental processes, microstructural evolution, and performance optimization strategies. The study outlines the essential physical mechanisms underlying laser–material interactions, including rapid solidification and non-equilibrium phase transformations, and discusses how process parameters influence the dynamic behavior of the melt pool and the resulting microstructure. Additionally, innovative techniques for defect control and quality enhancement—such as real-time multi-modal monitoring, in-situ diagnostics, and post-processing repair methods—are critically evaluated. The integration of multidisciplinary approaches, including digital twin technology, machine learning-based optimization, and advanced modeling techniques, is highlighted as a key driver for bridging the gap between laboratory research and industrial-scale production. Future research directions are identified in multi-material fabrication, intelligent closed-loop control, and sustainable manufacturing, paving the way for the next generation of high-performance, low-carbon, and net-zero emission manufacturing systems.

Graphical Abstract