Fusion-based Additive Manufacturing for Processing Aluminum Alloys: State-of-the-Art and Challenges

Starting early 2015, the fusion-based additive manufacturing of Al alloys has been developing at an ever faster pace after undergoing a comparatively slow start with respect to other metallic materials. This paper reviews the recent developments with the aim of identifying major challenges and opportunities for future work. Laser Beam Melting proves the most useful technique for the additive fabrication of Al components with strongly out-of-equilibrium microstructures and potentially enhanced mechanical behavior. Laser Cladding is also promising for specific applications such as repairs and coatings. However, a deeper understanding of the thermal history during fabrication is still needed to further optimize the microstructures and usage properties. The design of new high strength alloys and of Al-matrix composites, and the development of better adapted post-processing procedures to take greater advantage of the specificities of fusion-based additive techniques are two other important issues in view of reaching the full potential of additive Al components.