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This report provides comprehensive research on Additive ManufacturingAdditive manufacturing (AM) techniques for fabricating lightweight metal alloys (Al-Al2O3, etc.) and composites. It delves into their manufacturing processesProcess (Powder Bed Fusion, Electron Beam Melting, Wire Arc Additive ManufacturingWire arc additive manufacturing, etc.), challenges faced in manufacturing (low and high volume, etc.), advantages and disadvantages, comparison with traditional methods, and applications. AM enables unparalleled design freedom for lightweight structures, though the as-built components often show reduced fatigue life compared to their wrought counterparts. The work also highlights the indispensable role of post-processing (e.g., Hot Isostatic PressingHot isostatic pressing (HIP)) in eliminating porosity to achieve top mechanical integrity. The work also discusses the future of the field, which is evidently pointing toward AIArtificial Intelligence (AI)-driven in-situ monitoring and discoveries. Here, a comparison between Powder Bed Fusion Additive ManufacturingAdditive manufacturing and traditional methods (cast, wrought) is also provided, showcasing different propertiesProperties and other aspects.

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Additive Manufacturing for Lightweight Metal Alloys and Composite Materials: Processes, Performance, Applications, and Future

  • 会议论文

  • 发表日期：

    2026年

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  • Megh Raval,
  • Raj Pandya,
  • Soham Panchal,
  • Vishvesh Badheka

摘要

This report provides comprehensive research on Additive ManufacturingAdditive manufacturing (AM) techniques for fabricating lightweight metal alloys (Al-Al2O3, etc.) and composites. It delves into their manufacturing processesProcess (Powder Bed Fusion, Electron Beam Melting, Wire Arc Additive ManufacturingWire arc additive manufacturing, etc.), challenges faced in manufacturing (low and high volume, etc.), advantages and disadvantages, comparison with traditional methods, and applications. AM enables unparalleled design freedom for lightweight structures, though the as-built components often show reduced fatigue life compared to their wrought counterparts. The work also highlights the indispensable role of post-processing (e.g., Hot Isostatic PressingHot isostatic pressing (HIP)) in eliminating porosity to achieve top mechanical integrity. The work also discusses the future of the field, which is evidently pointing toward AIArtificial Intelligence (AI)-driven in-situ monitoring and discoveries. Here, a comparison between Powder Bed Fusion Additive ManufacturingAdditive manufacturing and traditional methods (cast, wrought) is also provided, showcasing different propertiesProperties and other aspects.