Review on laser directed energy deposited aluminum alloys

Abstract

The lightweight aluminum (Al) alloys have been widely used in frontier fields like aerospace and automotive industries, which attracts great interest in additive manufacturing to process high-value Al parts. As a mainstream additive manufacturing technique, laser directed energy deposition (LDED) shows good scalability to meet requirements for large-format components manufacturing and repairing. However, LDED Al alloys are highly challenging due to the inherent poor printability (e.g., low laser absorption, high oxidation sensitivity and cracking tendency). To further promote the development of LDED high-performance Al alloys, this review gains a deep understanding of the challenges and strategies to improve printability in LDED Al alloys. The porosity, cracking, distortion, inclusions, elements evaporation and resultant inferior mechanical properties (than laser powder bed fusion) are the key challenges in LDED Al alloys. Processing parameter optimizations, in-situ alloy design, reinforcing particle addition and field assistance are the efficient approaches to improve the printability and performance of LDED Al alloys. The underlying correlations between processes, alloy innovation, characteristic microstructures, and achievable performances in LDED Al alloys are discussed. The benchmarking mechanical properties and primary strengthening mechanism of LDED Al alloys are summarized. This review aims to provide a critical and in-depth evaluation of current progress in LDED Al alloys. The future opportunities and perspectives in LDED high-performance Al alloys are also outlooked.

A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths

“…Figure 23b illustrates an example of crack formation in a single bead due to an improper selection of laser power. Using wire feedstock instead of powder minimizes the formation of gas-trapped pores, and their formation is mostly observed in materials that readily oxidize (e.g., aluminum alloys) [47,61,63,[171][172][173]. The most predominant type of pore observed in W-LDED is due to the gap formed between adjacent beads when employing an incorrect lateral or vertical overlap ratio attributed to the bead's aspect ratio, as explained in Section 5.2.…”

Numerical Simulation of Lost-Foam Casting for Key Components of A356 Aluminum Alloy in New Energy Vehicles

“…Given that lightweighting is a pivotal approach for energy conservation and emission reduction in hybrid vehicles, as well as for extending the driving range of electric vehicles, the aluminum alloy stands out for its outstanding mechanical properties and corrosion resistance [9,10]. This enables the A356 alloy to fulfill performance requirements while simultaneously reducing vehicle weight to enhance driving range [11,12]. Therefore, the main research direction for manufacturing motor casings is the adoption of aluminum alloy lost-foam casting.…”