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<p>This review systematically analyzes selective laser melting (SLM) of superalloys, focusing on the interrelationship between processing parameters, microstructural evolution, mechanical properties, and defect mitigation. Unlike prior reviews limited to individual alloy systems or empirical case studies, this work offers a comparative assessment of nickel-, cobalt-, and iron-based superalloys. The review highlights the critical role of laser processing parameters, such as scan speed, laser power, hatch spacing, and layer thickness, governing the formation of key defects including porosity, hot cracking, and lack of fusion. It further establishes the effectiveness of volumetric energy density (VED) as a unified and predictive metric for correlating process conditions with defect morphology and microstructural heterogeneity. Additionally, it underscores the quantitative relationships between thermal gradients during solidification and the resulting anisotropy in grain structures across different classes of superalloys. The review further identifies Hot Isostatic Pressing (HIP) and laser peening as effective post-processing techniques for reducing residual stresses and healing process-induced defects. Industrial relevance is demonstrated through sector-specific applications in aerospace, energy, biomedical, and automotive domains, highlighting alloy-performance alignment and qualification challenges. This work presents a comprehensive and integrated structure for understanding and optimizing the selective laser melting (SLM) of superalloys. It serves as a valuable resource for researchers and industry practitioners seeking to enhance process reliability, improve part performance, and advance the scalability of SLM for industrial applications.</p>

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Additive manufacturing of superalloys via selective laser melting: process–structure–property relationships, defect control, and industrial prospects

  • 期刊论文

  • 发表日期：

    2026年2月24日

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  • Sodiq Kareem,
  • Justus Anaele,
  • Tolulope Adewole,
  • Ifeyinwa Ibekwe,
  • Moses Olayiwola,
  • Michael Bodunrin

摘要

This review systematically analyzes selective laser melting (SLM) of superalloys, focusing on the interrelationship between processing parameters, microstructural evolution, mechanical properties, and defect mitigation. Unlike prior reviews limited to individual alloy systems or empirical case studies, this work offers a comparative assessment of nickel-, cobalt-, and iron-based superalloys. The review highlights the critical role of laser processing parameters, such as scan speed, laser power, hatch spacing, and layer thickness, governing the formation of key defects including porosity, hot cracking, and lack of fusion. It further establishes the effectiveness of volumetric energy density (VED) as a unified and predictive metric for correlating process conditions with defect morphology and microstructural heterogeneity. Additionally, it underscores the quantitative relationships between thermal gradients during solidification and the resulting anisotropy in grain structures across different classes of superalloys. The review further identifies Hot Isostatic Pressing (HIP) and laser peening as effective post-processing techniques for reducing residual stresses and healing process-induced defects. Industrial relevance is demonstrated through sector-specific applications in aerospace, energy, biomedical, and automotive domains, highlighting alloy-performance alignment and qualification challenges. This work presents a comprehensive and integrated structure for understanding and optimizing the selective laser melting (SLM) of superalloys. It serves as a valuable resource for researchers and industry practitioners seeking to enhance process reliability, improve part performance, and advance the scalability of SLM for industrial applications.