High-Performance Aluminum-Based Materials Processed by Laser Powder Bed Fusion: Process, Microstructure, Defects and Properties Coordination

Significant contributions have been made to understanding the processing of various metal materials using laser powder bed fusion (LPBF) for the design and fabrication of high-performance metal components in many fields. For laser additive manufacturing, aluminum-based materials are regarded as difficult-to-fabricate materials because of their special physical properties, including low density, low laser absorption, high thermal conductivity, and ease of oxidation. Currently, LPBF-formed structural materials require high densification, fine grains, high specific strength, high ductility, and optimized physical or chemical properties. Therefore, comprehensive understanding of the fabrication and performance of Al-based materials processed by LPBF is of significant value. This paper covers emerging research on aluminum-based materials using LPBF, providing an overall view of the basic scientific mechanisms behind manufacturing. The state-of-the-art researches of aluminum-based materials for LPBF formability as well as the microstructures, properties and corresponding metallurgical mechanisms are reviewed. The mechanisms of some of the main defects (pores, cracks, balling, and oxide inclusions) and control measures are also discussed. A summary and outlook for the further development of Al-based materials for LPBF are addressed.