Lightweight aluminum (Al) alloys have been widely used in frontier fields like aerospace and automotive industries, which attracts great interest in additive manufacturing (AM) to process high-value Al parts. As a mainstream AM technique, laser-directed energy deposition (LDED) shows good scalability to meet the requirements for large-format component manufacturing and repair. However, LDED Al alloys are highly challenging due to their 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 offers a deep understanding of the challenges and strategies to improve printability in LDED Al alloys. The porosity, cracking, distortion, inclusions, element evaporation and resultant inferior mechanical properties (worse 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 improving 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 benchmark 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. Future opportunities and perspectives in LDED high-performance Al alloys are also outlined.
Poudel A, Yasin M S, Ye J F, Liu J, Vinel A, Shao S and Shamsaei N 2022 Feature-based volumetric defect classification in metal additive manufacturing Nat. Commun. 13 6369
Qu M L, Guo Q L, Escano L I, Nabaa A, Hojjatzadeh S M H, Young Z A and Chen L Y 2022 Controlling process instability for defect lean metal additive manufacturing Nat. Commun. 13 1079
Saccone M A, Gallivan R A, Narita K, Yee D W and Greer J R 2022 Additive manufacturing of micro-architected metals via hydrogel infusion Nature 612 685–90
Sui S, Chew Y, Weng F, Tan C L, Du Z L and Bi G J 2022 Study of the intrinsic mechanisms of nickel additive for grain refinement and strength enhancement of laser aided additively manufactured Ti–6Al–4V Int. J. Extrem. Manuf. 4 035102
Tan C L, Weng F, Sui S, Chew Y and Bi G J 2021 Progress and perspectives in laser additive manufacturing of key aeroengine materials Int. J. Mach. Tools Manuf. 170 103804
Shao C W, Li H Y, Zhu Y K, Li P, Yu H Y, Zhang Z F, Gleiter H, McDonald A and Hogan J 2023 Nano-additive manufacturing of multilevel strengthened aluminum matrix composites Int. J. Extrem. Manuf. 5 015102
Wei C, Zhang Z Z, Cheng D X, Sun Z, Zhu M H and Li L 2021 An overview of laser-based multiple metallic material additive manufacturing: from macro- to micro-scales Int. J. Extrem. Manuf. 3 012003
Tan C L, Deng C, Li S, Abena A, Jamshidi P, Essa K, Wu L K, Xu G H, Attallah M M and Liu J 2022 Mechanical property and biological behaviour of additive manufactured TiNi functionally graded lattice structure Int. J. Extrem. Manuf. 4 045003
Sokoluk M, Cao C Z, Pan S H and Li X C 2019 Nanoparticle-enabled phase control for arc welding of unweldable aluminum alloy 7075 Nat. Commun. 10 98
Hu Y N et al 2022 Inhibiting weld cracking in high-strength aluminium alloys Nat. Commun. 13 5816
Sun W W, Zhu Y M, Marceau R, Wang L Y, Zhang Q, Gao X and Hutchinson C 2019 Precipitation strengthening of aluminum alloys by room-temperature cyclic plasticity Science 363 972–5
Bandyopadhyay A, Mitra I, Avila J D, Upadhyayula M and Bose S 2023 Porous metal implants: processing, properties, and challenges Int. J. Extrem. Manuf. 5 032014
Zhao C L, Bai Y C and Wang H 2023 Feasibility and reliability of laser powder bed fused AlSi10Mg/wrought AA6061 hybrid aluminium alloy component Int. J. Precis. Eng. Manuf. 10 959–77
Wang D, Feng Y W, Liu L Q, Wei X M, Yang Y Q, Yuan P, Liu Y, Han C J and Bai Y C 2022 Influence mechanism of process parameters on relative density, microstructure, and mechanical properties of low Sc-content Al-Mg-Sc-Zr alloy fabricated by selective laser melting Chin. J. Mech. Eng. 1 100034
Li S S et al 2023 Development and applications of aluminum alloys for aerospace industry J. Mater. Res. Technol. 27 944–83
Zhu Z G, Hu Z H, Seet H L, Liu T T, Liao W H, Ramamurty U and Ling Nai S M 2023 Recent progress on the additive manufacturing of aluminum alloys and aluminum matrix composites: microstructure, properties, and applications Int. J. Mach. Tools Manuf. 190 104047
Wang Q Z et al 2022 Effect of laser additive manufacturing on the microstructure and mechanical properties of TiB2 reinforced Al-Cu matrix composite Mater. Sci. Eng. A 840 142950
Zhang C, Zhu J K, Zheng H, Li H, Liu S and Cheng G J 2020 A review on microstructures and properties of high entropy alloys manufactured by selective laser melting Int. J. Extrem. Manuf. 2 032003
Zhang C, Li Y F, Gao M and Zeng X Y 2018 Wire arc additive manufacturing of Al-6Mg alloy using variable polarity cold metal transfer arc as power source Mater. Sci. Eng. A 711 415–23
Ansari M, Jabari E and Toyserkani E 2021 Opportunities and challenges in additive manufacturing of functionally graded metallic materials via powder-fed laser directed energy deposition: a review J. Mater. Process. Technol. 294 117117
Chen Y, Jian Z Y, Ren Y M, Li K, Dang B and Guo L X 2023 Influence of TiB2 volume fraction on SiCp/AlSi10Mg composites by LPBF: microstructure, mechanical, and physical properties J. Mater. Res. Technol. 23 3697–710
Zheng D D, Li Z, Jiang Y L, Li R K, Wu Y J, Tu Y X, Cheng X, Fu P H, Peng L M and Tang H B 2022 Effect of multiple thermal cycles on the microstructure evolution of GA151K alloy fabricated by laser-directed energy deposition Addit. Manuf. 57 102957
Svetlizky D, Zheng B L, Vyatskikh A, Das M, Bose S, Bandyopadhyay A, Schoenung J M, Lavernia E J and Eliaz N 2022 Laser-based directed energy deposition (DED-LB) of advanced materials Mater. Sci. Eng. A 840 142967
Fu R, Liang Y, Han Q, Guo Y, Lei H and Liu C 2023 Strengthening and fracturing mechanisms of laser-directed energy deposited Al-7075 alloy Mater. Sci. Eng. A 881 145433
Piscopo G and Iuliano L 2022 Current research and industrial application of laser powder directed energy deposition Int. J. Adv. Manuf. Technol. 119 6893–917
Tan C L, Chew Y, Weng F, Sui S, Ng F L, Liu T and Bi G J 2022 Laser aided additive manufacturing of spatially heterostructured steels Int. J. Mach. Tools Manuf. 172 103817
Gradl P, Tinker D C, Park A, Mireles O R, Garcia M, Wilkerson R and Mckinney C 2022 Robust metal additive manufacturing process selection and development for aerospace components J. Mater. Eng. Perform. 31 6013–44
Wang Z H, Lin X, Tang Y, Kang N, Gao X H, Shi S Q and Huang W D 2021 Laser-based directed energy deposition of novel Sc/Zr-modified Al-Mg alloys: columnar-to-equiaxed transition and aging hardening behavior J. Mater. Sci. Technol. 69 168–79
Pan Q Y, Kapoor M, Mileski S, Carsley J and Lou X Y 2021 Technical basis of using laser direct energy deposition as a high-throughput combinatorial method for DC-cast Al-Mn alloy development Mater. Des. 212 110290
Singh A K, Mundada Y, Bajaj P, Wilms M B, Patil J P, Mishra S K, Jägle E A and Arora A 2022 Investigation of temperature distribution and solidification morphology in multilayered directed energy deposition of Al-0.5Sc-0.5Si alloy Int. J. Heat Mass Transfer 186 122492
Li P X, Cai R, Yang G, Wang T Q, Han S S, Zhang S C, Wang W and Meng Q S 2021 Mechanically strong, stiff, and yet ductile AlSi7Mg/graphene composites by laser metal deposition additive manufacturing Mater. Sci. Eng. A 823 141749
Xi X, Chen B, Tan C W, Song X G and Feng J C 2020 Microstructure and mechanical properties of SiC reinforced AlSi10Mg composites fabricated by laser metal deposition J. Manuf. Process. 58 763–74
Li J, Cheng X, Li Z, Zong X, Zhang S Q and Wang H M 2018 Improving the mechanical properties of Al-5Si-1Cu-Mg aluminum alloy produced by laser additive manufacturing with post-process heat treatments Mater. Sci. Eng. A 735 408–17
Li L B, Yuan T C and Yuan X X 2022 The microstructure tailoring and property improving of directed energy deposited Al-Zn-Mg-Cu alloy modified with various Si and ZrO2 contents Mater. Charact. 188 111896
Chen B, Xi X, Gu T, Tan C W and Song X G 2020 Influence of heat treatment on microstructure evolution and mechanical properties of TiB2/Al 2024 composites fabricated by directed energy deposition J. Mater. Res. Technol. 9 14223–36
Svetlizky D, Zheng B L, Buta T, Zhou Y Z, Golan O, Breiman U, Haj-Ali R, Schoenung J M, Lavernia E J and Eliaz N 2020 Directed energy deposition of Al 5xxx alloy using laser engineered net shaping (LENS®) Mater. Des. 192 108763
Altıparmak S C, Yardley V A, Shi Z S and Lin J G 2021 Challenges in additive manufacturing of high-strength aluminium alloys and current developments in hybrid additive manufacturing Int. J. Lightwave Mater. Manuf. 4 246–61
Liu X H, Liu Y Z, Zhou Z G, Luo W Y and Zeng Z Y B 2022 Enhanced printability and strength of unweldable AA2024-based nanocomposites fabricated by laser powder bed fusion via nano-TiC-induced grain refinement Mater. Sci. Eng. A 856 144010
Liu X H, Liu Y Z, Zhou Z Q and Zhan Q K 2022 Enhanced strength and ductility in Al-Zn-Mg-Cu alloys fabricated by laser powder bed fusion using a synergistic grain-refining strategy J. Mater. Sci. Technol. 124 41–52
Sun T T, Chen J, Wu Y, Wang M L, Fu Y N, Wang H Z and Wang H W 2022 Achieving excellent strength of the LPBF additively manufactured Al–Cu–Mg composite via in-situ mixing TiB2 and solution treatment Mater. Sci. Eng. A 850 143531
Li D H, Zhang Z Q, Li S C, Yang J M, Zhang S Y, Bian X L, Zhang Y Q, Qi L and Ojo O A 2023 Microstructure, mechanical properties and fatigue crack growth behavior of an Al-Zn-Mg-Cu-Si-Zr-Er alloy fabricated by laser powder bed fusion Int. J. Fatigue 172 107636
Chen Y, Xiao C W, Zhu S, Li Z W, Yang W X, Zhao F, Yu S F and Shi Y S 2022 Microstructure characterization and mechanical properties of crack-free Al-Cu-Mg-Y alloy fabricated by laser powder bed fusion Addit. Manuf. 58 103006
Li X W, Li D W, Li G and Cai Q Z 2022 Microstructure, mechanical properties, aging behavior, and corrosion resistance of a laser powder bed fusion fabricated Al-Zn-Mg-Cu-Ta alloy Mater. Sci. Eng. A 832 142364
Cordova L, Bor T, de Smit M, Carmignato S, Campos M and Tinga T 2020 Effects of powder reuse on the microstructure and mechanical behaviour of Al–Mg–Sc–Zr alloy processed by laser powder bed fusion (LPBF) Addit. Manuf. 36 101625
Zhang Z Q, Sun J E, Xia J Y, Wu J S, Chen Z B, Zhang B C, Li Z Q, Li X G and Zhang B W 2022 Anisotropic response in corrosion behavior of laser powder bed fusion Al-Mn-Mg-Sc-Zr alloy Corros. Sci. 208 110634
Rometsch P A, Zhu Y M, Wu X H and Huang A J 2022 Review of high-strength aluminium alloys for additive manufacturing by laser powder bed fusion Mater. Des. 219 110779
Aboulkhair N T, Simonelli M, Parry L, Ashcroft I, Tuck C and Hague R 2019 3D printing of Aluminium alloys: additive Manufacturing of Aluminium alloys using selective laser melting Prog. Mater. Sci. 106 100578
Zhang J L, Song B, Wei Q S, Bourell D and Shi Y S 2019 A review of selective laser melting of aluminum alloys: processing, microstructure, property and developing trends J. Mater. Sci. Technol. 35 270–84
Liu T S, Qiu F, Yang H Y, Liu S, Jiang Q C and Zhang L C 2023 Exploring the potential of FSW-ed Al–Zn–Mg–Cu-based composite reinforced by trace in-situ nanoparticles in manufacturing workpiece with customizable size and high mechanical performances Composites B 250 110425
Liu T S, Qiu F, Dong B X, Geng R, Zha M, Yang H Y, Shu S L and Jiang Q C 2021 Role of trace nanoparticles in establishing fully optimized microstructure configuration of cold-rolled Al alloy Mater. Des. 206 109743
Dong B X, Li Q, Wang Z F, Liu T S, Yang H Y, Shu S L, Chen L Y, Qiu F, Jiang Q C and Zhang L C 2021 Enhancing strength-ductility synergy and mechanisms of Al-based composites by size-tunable in-situ TiB2 particles with specific spatial distribution Composites B 217 108912
Fan X B and Yuan S J 2022 Innovation for forming aluminum alloy thin shells at ultra-low temperature by the dual enhancement effect Int. J. Extrem. Manuf. 4 033001
Kasuga M, Sano T and Hirose A 2019 Grain refining in weld metal using short-pulsed laser ablation during CW laser welding of 2024-T3 aluminum alloy Int. J. Extrem. Manuf. 1 045003
Svetlizky D, Zheng B L, Steinberg D M, Schoenung J M, Lavernia E J and Eliaz N 2022 The influence of laser directed energy deposition (DED) processing parameters for Al5083 studied by central composite design J. Mater. Res. Technol. 17 3157–71
Zavala-Arredondo M, Boone N, Willmott J, Childs D T D, Ivanov P, Groom K M and Mumtaz K 2017 Laser diode area melting for high speed additive manufacturing of metallic components Mater. Des. 117 305–15
Da Silva A et al 2022 Influence of aluminium powder aging on directed energy deposition Mater. Des. 218 110677
Ghasemi A, Fereiduni E, Balbaa M, Jadhav S D, Elbestawi M and Habibi S 2021 Influence of alloying elements on laser powder bed fusion processability of aluminum: a new insight into the oxidation tendency Addit. Manuf. 46 102145
Kotadia H R, Gibbons G, Das A and Howes P D 2021 A review of laser powder bed fusion additive manufacturing of aluminium alloys: microstructure and properties Addit. Manuf. 46 102155
Capozzi L C, Sivo A and Bassini E 2022 Powder spreading and spreadability in the additive manufacturing of metallic materials: a critical review J. Mater. Process. Technol. 308 117706
Coeck S, Bisht M, Plas J and Verbist F 2019 Prediction of lack of fusion porosity in selective laser melting based on melt pool monitoring data Addit. Manuf. 25 347–56
Li L B, Yuan T C and Yuan X X 2023 The microstructure regulation and property enhancement of directed energy deposited Al-Zn-Mg-Cu-Si-Zr alloy with various Zr contents Mater. Chem. Phys. 297 127318
Li Q, Dong B X, Liu T S, Yang H Y, Shu S L, Qiu F and Jiang Q C 2021 Insight into solidification microstructure control by trace TiCN–TiB2 particles for yielding fine-tuned nanoprecipitates in a hypoeutectic Al–Si–Mg alloy Mater. Sci. Eng. A 827 142093
Wu D J, Liu D H, Niu F Y, Miao Q Y, Zhao K, Tang B K, Bi G J and Ma G Y 2020 Al–Cu alloy fabricated by novel laser-tungsten inert gas hybrid additive manufacturing Addit. Manuf. 32 100954
Lv F, Shen L D, Liang H X, Xie D Q, Wang C J and Tian Z J 2019 Mechanical properties of AlSi10Mg alloy fabricated by laser melting deposition and improvements via heat treatment Optik 179 8–18
Gao Y, Zhao J B, Zhao Y H, Wang Z G, Song H W and Gao M Q 2019 Effect of processing parameters on solidification defects behavior of laser deposited AlSi10Mg alloy Vacuum 167 471–8
Martin J H, Yahata B D, Hundley J M, Mayer J A, Schaedler T A and Pollock T M 2017 3D printing of high-strength aluminium alloys Nature 549 365–9
Engler O and Miller-Jupp S 2016 Control of second-phase particles in the Al-Mg-Mn alloy AA 5083 J. Alloys Compd. 689 998–1010
Hu Z H, Nie X J, Qi Y, Zhang H and Zhu H H 2021 Cracking criterion for high strength Al–Cu alloys fabricated by selective laser melting Addit. Manuf. 37 101709
Dong B X, Li Q, Yang H Y, Liu T S, Qiu F, Shu S L, Jiang Q C and Zhang L C 2022 Synergistic optimization in solidification microstructure and mechanical performance of novel (TiCxNy − TiB2)p/Al nanocomposites: design, tuning and mechanism Composites A 155 106843
Ataee A, Li Y C, Brandt M and Wen C E 2018 Ultrahigh-strength titanium gyroid scaffolds manufactured by selective laser melting (SLM) for bone implant applications Acta Mater. 158 354–68
Tan C L et al 2023 Review on field assisted metal additive manufacturing Int. J. Mach. Tools Manuf. 189 104032
Takata N, Liu M L, Li H M, Suzuki A and Kobashi M 2022 Fast scanning calorimetry study of Al alloy powder for understanding microstructural development in laser powder bed fusion Mater. Des. 219 110830
Gong J Q, Wei K W, Liu M N, Song W J, Li X Y and Zeng X Y 2022 Microstructure and mechanical properties of AlSi10Mg alloy built by laser powder bed fusion/direct energy deposition hybrid laser additive manufacturing Addit. Manuf. 59 103160
Hagenlocher C, O’Toole P, Xu W, Brandt M, Easton M and Molotnikov A 2022 In process monitoring of the thermal profile during solidification in laser directed energy deposition of aluminium Addit. Manuf. Lett. 3 100084
Li L B, Yuan T C and Feng B 2023 The microstructures and mechanical properties of Al-Zn-Mg-Cu-Si-Zr alloy: a comparison between directed energy deposition and laser powder bed fusion Mater. Lett. 337 133959
Dong P, Vecchiato F, Yang Z, Hooper P A and Wenman M R 2021 The effect of build direction and heat treatment on atmospheric stress corrosion cracking of laser powder bed fusion 316L austenitic stainless steel Addit. Manuf. 40 101902
Wang X L, Sanchez-Mata O, Atabay S E, Muñiz-Lerma J A, Attarian Shandiz M and Brochu M 2021 Crystallographic orientation dependence of Charpy impact behaviours in stainless steel 316L fabricated by laser powder bed fusion Addit. Manuf. 46 102104
Da Silva A, Volpp J and Kaplan A F H 2021 The effects of laser irradiation on an aluminium powder stream in directed energy deposition Addit. Manuf. 41 101968
Singh A, Ramakrishnan A, Baker D, Biswas A and Dinda G P 2017 Laser metal deposition of nickel coated Al 7050 alloy J. Alloys Compd. 719 151–8
Kempen K, Thijs L, Van Humbeeck J and Kruth J P 2015 Processing AlSi10Mg by selective laser melting: parameter optimisation and material characterisation Mater. Sci. Technol. 31 917–23
Ding Y, Muñiz-Lerma J A, Trask M, Chou S, Walker A and Brochu M 2016 Microstructure and mechanical property considerations in additive manufacturing of aluminum alloys MRS Bull. 41 745–51
Kim H J and Shim D S 2022 Characterization of the deposit-foaming of pure aluminum and Al-Mg-0.7Si alloys using directed energy deposition based on their metallurgical characteristics and compressive behaviors Addit. Manuf. 59 103119
Ng G K L, Jarfors A E W, Bi G and Zheng H Y 2009 Porosity formation and gas bubble retention in laser metal deposition Appl. Phys. A 97 641–9
Bergman A, Fredriksson H and Shahani H 1988 The effect of gravity and temperature gradients on precipitation in immiscible alloys J. Mater. Sci. 23 1573–9
Wang M J, Ventzke V and Kashaev N 2022 Wire-based laser directed energy deposition of AA7075: effect of process parameters on microstructure and mechanical properties J. Mater. Res. Technol. 21 388–403
Zhao T et al 2021 Some factors affecting porosity in directed energy deposition of AlMgScZr-alloys Opt. Laser Technol. 143 107337
Rajan T P D, Pillai R M and Pai B C 2008 Functionally graded Al–Al3Ni in situ intermetallic composites: fabrication and microstructural characterization J. Alloys Compd. 453 L4–L7
Isik M, Avila J D and Bandyopadhyay A 2020 Alumina and tricalcium phosphate added CoCr alloy for load-bearing implants Addit. Manuf. 36 101553
Wolff S J, Lin S, Faierson E J, Liu W K, Wagner G J and Cao J 2017 A framework to link localized cooling and properties of directed energy deposition (DED)-processed Ti-6Al-4V Acta Mater. 132 106–17
Sterling A J, Torries B, Shamsaei N, Thompson S M and Seely D W 2016 Fatigue behavior and failure mechanisms of direct laser deposited Ti–6Al–4V Mater. Sci. Eng. A 655 100–12
Kasperovich G, Haubrich J, Gussone J and Requena G 2016 Correlation between porosity and processing parameters in TiAl6V4 produced by selective laser melting Mater. Des. 105 160–70
Zhu Z G, Ng F L, Seet H L and Nai S M L 2022 Selective laser melting of micron-sized niobium functionalized Al7075 alloy: element evaporation and grain refinement Mater. Sci. Eng. A 834 142595
Su Y T, Wang Y C and Shi J 2022 Microstructure and mechanical properties of laser DED produced crack-free Al 7075 alloy: effect of process parameters and heat treatment Mater. Sci. Eng. A 857 144075
DebRoy T, Wei H L, Zuback J S, Mukherjee T, Elmer J W, Milewski J O, Beese A M, Wilson-Heid A, De A and Zhang W 2018 Additive manufacturing of metallic components—process, structure and properties Prog. Mater. Sci. 92 112–224
Sames W J, List F A, Pannala S, Dehoff R R and Babu S S 2016 The metallurgy and processing science of metal additive manufacturing Int. Mater. Rev. 61 315–60
Svetlizky D, Das M, Zheng B L, Vyatskikh A L, Bose S, Bandyopadhyay A, Schoenung J M, Lavernia E J and Eliaz N 2021 Directed energy deposition (DED) additive manufacturing: physical characteristics, defects, challenges and applications Mater. Today 49 271–95
Benoit M J, Sun S D, Brandt M and Easton M A 2021 Processing window for laser metal deposition of Al 7075 powder with minimized defects J. Manuf. Process. 64 1484–92
Gonzalez L C, Tuominen J, Ahmed S, Patnamsetty M and Peura P 2022 Directed energy deposition of AA7075—effect of TiC nanoparticles on microstructure Results Mater. 16 100341
Eskin D G, Suyitno N and Katgerman L 2004 Mechanical properties in the semi-solid state and hot tearing of aluminium alloys Prog. Mater. Sci. 49 629–711
Thapliyal S, Agrawal P, Agrawal P, Nene S S, Mishra R S, McWilliams B A and Cho K C 2021 Segregation engineering of grain boundaries of a metastable Fe-Mn-Co-Cr-Si high entropy alloy with laser-powder bed fusion additive manufacturing Acta Mater. 219 117271
Stopyra W, Gruber K, Smolina I, Kurzynowski T and Kuźnicka B 2020 Laser powder bed fusion of AA7075 alloy: influence of process parameters on porosity and hot cracking Addit. Manuf. 35 101270
Bayoumy D, Schliephake D, Dietrich S, Wu X H, Zhu Y M and Huang A J 2021 Intensive processing optimization for achieving strong and ductile Al-Mn-Mg-Sc-Zr alloy produced by selective laser melting Mater. Des. 198 109317
Zhai Z Y, Pan W, Liang B, Liu Y T and Zhang Y Z 2022 Cracking behavior, microstructure and properties of selective laser melted Al-Mn-Mg-Sc-Zr alloy Crystals 12 565
Zhao D D, Løvvik O M, Marthinsen K and Li Y J 2018 Segregation of Mg, Cu and their effects on the strength of Al Σ5 (210)[001] symmetrical tilt grain boundary Acta Mater. 145 235–46
Zhou S Y, Su Y, Wang H, Enz J, Ebel T and Yan M 2020 Selective laser melting additive manufacturing of 7xxx series Al-Zn-Mg-Cu alloy: cracking elimination by co-incorporation of Si and TiB2 Addit. Manuf. 36 101458
Li L B, Li R D, Yuan T C, Chen C, Zhang Z J and Li X F 2020 Microstructures and tensile properties of a selective laser melted Al–Zn–Mg–Cu (Al7075) alloy by Si and Zr microalloying Mater. Sci. Eng. A 787 139492
Mercelis P and Kruth J 2006 Residual stresses in selective laser sintering and selective laser melting Rapid Prototy. J. 12 254–65
Li C, Liu Z Y, Fang X Y and Guo Y B 2018 Residual stress in metal additive manufacturing Proc. CIRP 71 348–53
Deng S H, Zhao H J, Li R D, Shao J Q, Li J N, Qi L, Ojo O A, Chen J Q, Zhang L N and Li W R 2022 Composition design of low hot-cracking susceptibility of Al-Zn-Mg-Sc alloy and its formability during laser additive manufacturing Mater. Charact. 193 112304
Zhou J T, Zhou X, Li H, Hu J W, Han X and Liu S 2022 In-situ laser shock peening for improved surface quality and mechanical properties of laser-directed energy-deposited AlSi10Mg alloy Addit. Manuf. 60 103177
Alimardani M, Toyserkani E, Huissoon J P and Paul C P 2009 On the delamination and crack formation in a thin wall fabricated using laser solid freeform fabrication process: an experimental–numerical investigation Opt. Lasers Eng. 47 1160–8
Zhang J K, Wang X Y, Paddea S and Zhang X 2016 Fatigue crack propagation behaviour in wire+arc additive manufactured Ti-6Al-4V: effects of microstructure and residual stress Mater. Des. 90 551–61
Gu D D, Rao X W, Dai D H, Ma C L, Xi L X and Lin K J 2019 Laser additive manufacturing of carbon nanotubes (CNTs) reinforced aluminum matrix nanocomposites: processing optimization, microstructure evolution and mechanical properties Addit. Manuf. 29 100801
Su J L, Jiang F L, Tan C L, Weng F, Ng F L, Goh M H, Xie H M, Liu J, Chew Y and Teng J 2023 Additive manufacturing of fine-grained high-strength titanium alloy via multi-eutectoid elements alloying Composites B 249 110399
Rometsch P A, Zhong H, Nairn K M, Jarvis T and Wu X H 2014 Characterization of a laser-fabricated hypereutectic Al–Sc alloy bar Scr. Mater. 87 13–16
Wen X L, Wang Q Z, Mu Q, Kang N, Sui S, Yang H O, Lin X and Huang W D 2019 Laser solid forming additive manufacturing TiB2 reinforced 2024Al composite: microstructure and mechanical properties Mater. Sci. Eng. A 745 319–25
Zhao T et al 2020 Laser metal deposition for additive manufacturing of AA5024 and nanoparticulate TiC modified AA5024 alloy composites prepared with balling milling process Opt. Laser Technol. 131 106438
Jiang B, Zhenglong L, Xi C, Peng L, Nannan L and Yanbin C 2019 Microstructure and mechanical properties of TiB2-reinforced 7075 aluminum matrix composites fabricated by laser melting deposition Ceram. Int. 45 5680–92
Lu X F, Lin X, Chiumenti M, Cervera M, Hu Y L, Ji X L, Ma L, Yang H O and Huang W D 2019 Residual stress and distortion of rectangular and S-shaped Ti-6Al-4V parts by directed energy deposition: modelling and experimental calibration Addit. Manuf. 26 166–79
Corbin D J, Nassar A R, Reutzel E W, Beese A M and Michaleris P 2018 Effect of substrate thickness and preheating on the distortion of laser deposited Ti–6Al–4V J. Manuf. Sci. Eng. 140 061009
Amar H, Vignal V, Krawiec H, Josse C, Peyre P, da Silva S N and Dick L F 2011 Influence of the microstructure and laser shock processing (LSP) on the corrosion behaviour of the AA2050-T8 aluminium alloy Corros. Sci. 53 3215–21
Jeurgens L P H, Sloof W G, Tichelaar F D and Mittemeijer E J 2002 Structure and morphology of aluminium-oxide films formed by thermal oxidation of aluminium Thin Solid Films 418 89–101
Jeurgens L P H, Sloof W G, Tichelaar F D, Borsboom C G and Mittemeijer E J 1999 Determination of thickness and composition of aluminium-oxide overlayers on aluminium substrates Appl. Surf. Sci. 144–145 11–15
Paravan C, Verga A, Maggi F and Galfetti L 2019 Accelerated ageing of micron- and nano-sized aluminum powders: metal content, composition and non-isothermal oxidation reactivity Acta Astronaut. 158 397–406
Mazur M 1992 Porosity in aluminium welds Weld. Int. 6 929–31
Atwood R C and Lee P D 2003 Simulation of the three-dimensional morphology of solidification porosity in an aluminium–silicon alloy Acta Mater. 51 5447–66
Voigt C, Ditscherlein L, Werzner E, Zienert T, Nowak R, Peuker U, Sobczak N and Aneziris C G 2018 Wettability of AlSi7Mg alloy on alumina, spinel, mullite and rutile and its influence on the aluminum melt filtration efficiency Mater. Des. 150 75–85
Chen L and Hwang S, S C 1989 Chemical kinetics and reaction mechanism of thermal decomposition of aluminum hydroxide and magnesium hydroxide at high temperature (973–1123 K) Ind. Eng. Chem. Res. 28 738–42
Muneoka H, Himeno S, Urabe K, Stauss S, Baba M, Suemoto T and Terashima K 2019 Dynamics of cavitation bubbles formed by pulsed-laser ablation plasmas near the critical point of CO2 J. Phys. D: Appl. Phys. 52 025201
Ibrahimkutty S, Wagener P, Dos Santos Rolo T, Karpov D, Menzel A, Baumbach T, Barcikowski S and Plech A 2015 A hierarchical view on material formation during pulsed-laser synthesis of nanoparticles in liquid Sci. Rep. 5 16313
Shi X, Ma S Y, Liu C M and Wu Q R 2017 Parameter optimization for Ti-47Al-2Cr-2Nb in selective laser melting based on geometric characteristics of single scan tracks Opt. Laser Technol. 90 71–79
Klassen A, Forster V E, Juechter V and Körner C 2017 Numerical simulation of multi-component evaporation during selective electron beam melting of TiAl J. Mater. Process. Technol. 247 280–8
Salehi M, Maleksaeedi S, Farnoush H, Sharon N M L, Meenashisundaram G K and Gupta M 2018 An investigation into interaction between magnesium powder and Ar gas: implications for selective laser melting of magnesium Powder Technol. 333 252–61
Zhirnov I, Kotoban D V and Gusarov A V 2018 Evaporation-induced gas-phase flows at selective laser melting Appl. Phys. A 124 157
Ramakrishnan A and Dinda G P 2020 Microstructural control of an Al–W aluminum matrix composite during direct laser metal deposition J. Alloys Compd. 813 152208
Liu Y, Liu C, Liu W S, Ma Y Z, Tang S W, Liang C P, Cai Q S and Zhang C 2019 Optimization of parameters in laser powder deposition AlSi10Mg alloy using Taguchi method Opt. Laser Technol. 111 470–80
Wang A, Wei Q L, Luo S, Tang Z J, Yang H H, Wu Y, Leung C L A, Lee P D, Wang H W and Wang H Z 2023 Blue laser directed energy deposition of aluminum with synchronously enhanced efficiency and quality Addit. Manuf. Lett. 5 100127
Attar H, Ehtemam-Haghighi S, Kent D, Wu X H and Dargusch M S 2017 Comparative study of commercially pure titanium produced by laser engineered net shaping, selective laser melting and casting processes Mater. Sci. Eng. A 705 385–93
Tang Z J, Wei Q L, Gao Z Y, Yang H H, Wang A, Wan L, Luo C, Wu L, Wang H W and Wang H Z 2022 2000W Blue laser directed energy deposition of AlSi7Mg: process parameters, molten pool characteristics, and appearance defects Virtual Phys. Prototyp. 18 e2120405
Zediker M S, Fritz R D, Finuf M J and Pelaprat J M 2019 Stable keyhole welding of 1 mm thick copper with a 600 W blue laser system J. Laser Appl. 31 022404
Li J, Cheng X, Li Z, Zong X, Chen X H, Zhang S Q and Wang H M 2019 Microstructures and mechanical properties of laser additive manufactured Al-5Si-1Cu-Mg alloy with different layer thicknesses J. Alloys Compd. 789 15–24
Li Y M, Yang H O, Lin X, Huang W D, Li J G and Zhou Y H 2003 The influences of processing parameters on forming characterizations during laser rapid forming Mater. Sci. Eng. A 360 18–25
Gu T, Chen B, Tan C W and Feng J C 2019 Microstructure evolution and mechanical properties of laser additive manufacturing of high strength Al-Cu-Mg alloy Opt. Laser Technol. 112 140–50
Li W Z, Qian F, Li J Y, Zhu Y C, Liang Y J, Xu S, Li Y J and Cheng X W 2023 Design strategy for eliminating cracking and improving mechanical properties of Al-Mg-Si alloys fabricated by laser melting deposition Addit. Manuf. 68 103513
Bhagavatam A, Ramakrishnan A, Adapa V S K and Dinda G P 2018 Laser metal deposition of aluminum 7075 alloy Int. J. Mater. Sci. Res. 2 50–55
Wang Z H, Lin X, Kang N, Chen J, Tang Y, Tan H, Yu X B, Yang H O and Huang W D 2021 Directed energy deposition additive manufacturing of a Sc/Zr-modified Al–Mg alloy: effect of thermal history on microstructural evolution and mechanical properties Mater. Sci. Eng. A 802 140606
Guo N, Wu D, Wang G H, Cheng Q, Fu Y L and Yu M Q 2022 Investigation on underwater wire-feed laser deposition of 5052 aluminum alloy J. Manuf. Process. 76 687–94
Chen L Q, Yao X L, Tan C L, He W Y, Su J L, Weng F, Chew Y, Ng N P H and Moon S K 2023 In-situ crack and keyhole pore detection in laser directed energy deposition through acoustic signal and deep learning Addit. Manuf. 69 103547
Johnson N S, Vulimiri P S, To A C, Zhang X, Brice C A, Kappes B B and Stebner A P 2020 Invited review: machine learning for materials developments in metals additive manufacturing Addit. Manuf. 36 101641
Qi X B, Chen G F, Li Y, Cheng X and Li C P 2019 Applying neural-network-based machine learning to additive manufacturing: current applications, challenges, and future perspectives Engineering 5 721–9
Caiazzo F and Caggiano A 2018 Laser direct metal deposition of 2024 Al alloy: trace geometry prediction via machine learning Materials 11 444
García-Moreno A I, Alvarado-Orozco J M, Ibarra-Medina J and Martínez-Franco E 2021 Ex-situ porosity classification in metallic components by laser metal deposition: a machine learning-based approach J. Manuf. Process. 62 523–34
Jin Z Q, Zhang Z Z, Demir K and Gu G X 2020 Machine learning for advanced additive manufacturing Matter 3 1541–56
Yang H N, Wang S R, Duan X N, Wang G Q, Gao S P and Xiao Z 2023 Microstructure and mechanical properties of Al–18Si–10Cu–10Ni–5Mn(−5Mg) heat-resistant aluminum alloys prepared by laser-directed energy deposition Mater. Sci. Eng. A 883 145512
Hua Q, Wang W J, Li R D, Zhu H B, Lin Z H, Xu R, Yuan T C and Liu K 2022 Microstructures and mechanical properties of Al-Mg-Sc-Zr alloy additively manufactured by laser direct energy deposition Chin. J. Mech. Eng. 1 100057
Xiao X, Guo Y J, Zhang R F, Bayoumy D, Shen H P, Li J F, Gan K F, Zhang K, Zhu Y M and Huang A J 2022 Achieving uniform plasticity in a high strength Al-Mn-Sc based alloy through laser-directed energy deposition Addit. Manuf. 60 103273
Yang K V, Shi Y J, Palm F, Wu X H and Rometsch P 2018 Columnar to equiaxed transition in Al-Mg(-Sc)-Zr alloys produced by selective laser melting Scr. Mater. 145 113–7
Schmidtke K, Palm F, Hawkins A and Emmelmann C 2011 Process and mechanical properties: applicability of a scandium modified al-alloy for laser additive manufacturing Phys. Proc. 12 369–74
Fujikawa S I, Sugaya M, Takei H and Hirano K I 1979 Solid solubility and residual resistivity of scandium in aluminum J. Less Common Met. 63 87–97
Deane K, Kampe S L, Swenson D and Sanders P G 2017 Precipitate evolution and strengthening in supersaturated rapidly solidified Al-Sc-Zr alloys Metall. Mater. Trans. A 48 2030–9
Scipioni Bertoli U, Guss G, Wu S, Matthews M J and Schoenung J M 2017 In-situ characterization of laser-powder interaction and cooling rates through high-speed imaging of powder bed fusion additive manufacturing Mater. Des. 135 385–96
Hunt J D 1984 Steady state columnar and equiaxed growth of dendrites and eutectic Mater. Sci. Eng. 65 75–83
Shi Y J, Rometsch P, Yang K, Palm F and Wu X H 2017 Characterisation of a novel Sc and Zr modified Al–Mg alloy fabricated by selective laser melting Mater. Lett. 196 347–50
Deschamps A, Lae L and Guyot P 2007 In situ small-angle scattering study of the precipitation kinetics in an Al–Zr–Sc alloy Acta Mater. 55 2775–83
Zhao T et al 2018 Ageing response of an Al-Mg-Mn-Sc-Zr alloy processed by laser metal deposition in thin-wall structures Vacuum 158 121–5
Dong B L, Xia Y H, Cai X Y, Lin S B and Fan C L 2023 Addition of Sc in wire-based directed energy deposition of Al–Mg–Zn–Cu alloy: microalloying to refine grains and improve mechanical properties Addit. Manuf. 67 103494
Plotkowski A, Rios O, Sridharan N, Sims Z, Unocic K, Ott R T, Dehoff R R and Babu S S 2017 Evaluation of an Al-Ce alloy for laser additive manufacturing Acta Mater. 126 507–19
Yang Z W, Chen C, Li D, Wu Y Y, Geng Z W, Konakov V and Zhou K C 2023 An additively manufactured heat-resistant Al-Ce-Sc-Zr alloy: microstructure, mechanical properties and thermal stability Mater. Sci. Eng. A 872 144965
Ma X D, Yang H Y, Dong B X, Shu S L, Wang Z, Shao Y, Jiang Q C and Qiu F 2023 Novel method to achieve synergetic strength–ductility improvement of Al–Cu alloy by in situ TiC–TiB2 particles via direct reaction synthesis Mater. Sci. Eng. A 869 144810
Li S S, Qiu F, Yang H Y, Liu S, Liu T S, Chen L Y and Jiang Q C 2022 Strengthening of dislocation and precipitation for high strength and toughness casting Al–Zn–Mg–Cu alloy via trace TiB2+ TiC particles Mater. Sci. Eng. A 857 144107
Li Q, Qiu F, Dong B X, Geng R, Lv M M, Zhao Q L and Jiang Q C 2018 Fabrication, microstructure refinement and strengthening mechanisms of nanosized SiCP/Al composites assisted ultrasonic vibration Mater. Sci. Eng. A 735 310–7
Lin T C, Cao C Z, Sokoluk M, Jiang L, Wang X, Schoenung J M, Lavernia E J and Li X C 2019 Aluminum with dispersed nanoparticles by laser additive manufacturing Nat. Commun. 10 4124
Liu W Q, Cao C Z, Xu J Q, Wang X J and Li X C 2016 Molten salt assisted solidification nanoprocessing of Al-TiC nanocomposites Mater. Lett. 185 392–5
Wen X L, Chen B, Chen Z, Lin X, Yang H O, Kang N, Wang Q Z, Wang W L and Huang W D 2022 Structural evolution and mechanical properties of TiB2 reinforced 2024Al composite stimulated by heat treatment Mater. Sci. Eng. A 847 143290
Li Q, Qiu F, Gao Y Y, Dong B X, Shu S L, Lv M M, Yang H Y, Zhao Q L and Jiang Q C 2019 Microstructure refinement and strengthening mechanisms of bimodal-sized and dual-phased (TiCn-Al3Tim)/Al hybrid composites assisted ultrasonic vibration J. Alloys Compd. 788 1309–21
Mi G Y, Xiang Y, Wang C M, Xiong L D and Ouyang Q B 2023 Microstructure and mechanical properties of SiCp/Al composite fabricated by concurrent wire-powder feeding laser deposition J. Mater. Res. Technol. 22 66–79
Li L B, Luo L X and Wu Y Y 2023 The microstructure regulation and property enhancement of directed energy deposited Al-Zn-Mg-Cu alloy modified with fixed Si fraction and various TiC contents Mater. Today Commun. 34 105182
Tan H, Hao D P, Al-Hamdani K, Zhang F Y, Xu Z K and Clare A T 2018 Direct metal deposition of TiB2/AlSi10Mg composites using satellited powders Mater. Lett. 214 123–6
Xu R, Li R D, Yuan T C, Zhu H B and Li P 2021 Microstructure and mechanical properties of TiC-reinforced Al–Mg–Sc–Zr composites additively manufactured by laser direct energy deposition Acta Metall. Sin. 35 411–24
Han C J, Babicheva R, Chua J D Q, Ramamurty U, Tor S B, Sun C N and Zhou K 2020 Microstructure and mechanical properties of (TiB+TiC)/Ti composites fabricated in situ via selective laser melting of Ti and B4C powders Addit. Manuf. 36 101466
Li N, Wang T, Zhang L X and Zhang L 2023 Coupling effects of SiC and TiB2 particles on crack inhibition in Al-Zn-Mg-Cu alloy produced by laser powder bed fusion J. Mater. Sci. Technol. 164 37–51
Leijon F, Johansson E, Lu J, Aling B, Skjervold S and Moverare J 2022 Investigation of Ti1−x(Zr, Ta, V, W)xB2 and Al3Ti1−x(Zr, V)x grain refiners in additively manufactured Al-2 wt%Cu alloys by a high throughput method Mater. Des. 222 111093
Chen B, Zhou X Y, Zhang B, Kondoh K, Li J S and Qian M 2020 Microstructure, tensile properties and deformation behaviors of aluminium metal matrix composites co-reinforced by ex-situ carbon nanotubes and in-situ alumina nanoparticles Mater. Sci. Eng. A 795 139930
AlMangour B, Grzesiak D, Cheng J Q and Ertas Y 2018 Thermal behavior of the molten pool, microstructural evolution, and tribological performance during selective laser melting of TiC/316L stainless steel nanocomposites: experimental and simulation methods J. Mater. Process. Technol. 257 288–301
Zaguliaev D, Konovalov S, Ivanov Y and Gromov V 2019 Effect of electron-plasma alloying on structure and mechanical properties of Al-Si alloy Appl. Surf. Sci. 498 143767
Jiang L, Li Z Q, Fan G L, Cao L L and Zhang D 2012 The use of flake powder metallurgy to produce carbon nanotube (CNT)/aluminum composites with a homogenous CNT distribution Carbon 50 1993–8
Sun T T, Wang H Z, Gao Z Y, Wu Y, Wang M L, Jin X Y, Alex Leung C L, Lee P D, Fu Y N and Wang H W 2022 The role of in-situ nano-TiB2 particles in improving the printability of noncastable 2024Al alloy Mater. Res. Lett. 10 656–65
Yi J C, Zhang X W, Liu G Z, Rao J H and Liu H 2023 Microstructure and dynamic microhardness of additively manufactured (TiB2+TiC)/AlSi10Mg composites with AlSi10Mg and B4C coated Ti powder J. Alloys Compd. 939 168718
Miao Q Y, Wu D J, Chai D S, Zhan Y, Bi G J, Niu F Y and Ma G Y 2020 Comparative study of microstructure evaluation and mechanical properties of 4043 aluminum alloy fabricated by wire-based additive manufacturing Mater. Des. 186 108205
Cui X J, Qi E Y, Sun Z G, Jia C B, Zeng Y and Wu S K 2022 Wire oscillating laser additive manufacturing of 2319 aluminum alloy: optimization of process parameters, microstructure, and mechanical properties Chin. J. Mech. Eng. 1 100035
Song G and Luo Z M 2011 The influence of laser pulse waveform on laser–TIG hybrid welding of AZ31B magnesium alloy Opt. Lasers Eng. 49 82–88
Steen W M 1980 Arc augmented laser processing of materials J. Appl. Phys. 51 5636–41
Wang L, Yao J H, Hu Y and Song S Y 2015 Suppression effect of a steady magnetic field on molten pool during laser remelting Appl. Surf. Sci. 351 794–802
Ma G Y, Liu X, Song C C, Niu F Y and Wu D J 2022 TiCp reinforced Ti6Al4V of follow-up synchronous electromagnetic induction-laser hybrid directed energy deposition: microstructure evolution and mechanical properties Addit. Manuf. 59 103087
Schneider A, Avilov V, Gumenyuk A and Rethmeier M 2013 Laser beam welding of aluminum alloys under the influence of an electromagnetic field Phys. Proc. 41 4–11
Liu Q C, Zhuang W and Sharp P K 2014 Fatigue life improvement of laser clad 7075 aluminium alloy by deep surface rolling technique Adv. Mater. Res. 891–892 115–20
Zhuang W, Liu Q, Djugum R, Sharp P K and Paradowska A 2014 Deep surface rolling for fatigue life enhancement of laser clad aircraft aluminium alloy Appl. Surf. Sci. 320 558–62
Zhang Y, Guo Y Q, Chen Y, Kang L, Cao Y B, Qi H B and Yang S P 2019 Ultrasonic-assisted laser metal deposition of the Al 4047Alloy Metals 9 1111
Li J C, Lin X, Kang N, Lu J L, Wang Q Z and Huang W D 2020 Microstructure, tensile and wear properties of a novel graded Al matrix composite prepared by direct energy deposition J. Alloys Compd. 826 154077
Shi S Q, Lin X, Wang L L, Wang Z N, Wei L, Yang H O, Tang Y and Huang W D 2023 Investigations of the processing–structure–performance relationships of an additively manufactured AlSi10Mg alloy via directed energy deposition J. Alloys Compd. 944 169050
Lin X, Yue T M, Yang H O and Huang W D 2005 Laser rapid forming of SS316L/Rene88DT graded material Mater. Sci. Eng. A 391 325–36
Wang X, Li L Q, Qu J Y and Tao W 2019 Microstructure and mechanical properties of laser metal deposited AlSi10Mg alloys Mater. Sci. Technol. 35 2284–93
Wang Z H, Lin X, Kang N, Hu Y L, Chen J and Huang W D 2020 Strength-ductility synergy of selective laser melted Al-Mg-Sc-Zr alloy with a heterogeneous grain structure Addit. Manuf. 34 101260
Tan C L et al 2023 Machine learning customized novel material for energy-efficient 4D printing Adv. Sci. 10 2206607
Chen R, Wang H M, He B, Tu Y X and Tang H B 2021 Effect of thermal cycling on microstructure and mechanical properties of 2A97 Al–Li alloy fabricated by direct laser deposition Vacuum 190 110299
Li J, Cheng X, Liu D, Zhang S Q, Li Z, He B and Wang H M 2018 Phase evolution of a heat-treatable aluminum alloy during laser additive manufacturing Mater. Lett. 214 56–59
Kürnsteiner P, Bajaj P, Gupta A, Wilms M B, Weisheit A, Li X S, Leinenbach C, Gault B, Jägle E A and Raabe D 2020 Control of thermally stable core-shell nano-precipitates in additively manufactured Al-Sc-Zr alloys Addit. Manuf. 32 100910
Liu T S, Qiu F, Yang H Y, Shu S L, Xie J F, Jiang Q C and Zhang L C 2023 Insights into the influences of nanoparticles on microstructure evolution mechanism and mechanical properties of friction-stir-welded Al 6061 alloys Mater. Sci. Eng. A 871 144929
Yang M J et al 2020 Quantified contribution of β’’ and β’ precipitates to the strengthening of an aged Al–Mg–Si alloy Mater. Sci. Eng. A 774 138776
Yang W C, Huang L P, Zhang R R, Wang M P, Li Z, Jia Y L, Lei R S and Sheng X F 2012 Electron microscopy studies of the age-hardening behaviors in 6005A alloy and microstructural characterizations of precipitates J. Alloys Compd. 514 220–33
Aboulkhair N T, Tuck C, Ashcroft I, Maskery I and Everitt N M 2015 On the precipitation hardening of selective laser melted AlSi10Mg Metall. Mater. Trans. A 46 3337–41
Brandl E, Heckenberger U, Holzinger V and Buchbinder D 2012 Additive manufactured AlSi10Mg samples using selective laser melting (SLM): microstructure, high cycle fatigue, and fracture behavior Mater. Des. 34 159–69
Kiani P, Dupuy A D, Ma K and Schoenung J M 2020 Directed energy deposition of AlSi10Mg: single track nonscalability and bulk properties Mater. Des. 194 108847
Lee T, Jeong W, Chung S, Kim J J, Lee D, Kim J and Ryu H J 2023 Role of B4C in the directed energy deposition of aluminum alloy 6061/B4C composite using core-shell powder for crack annihilation, pore mitigation, and grain refinement Addit. Manuf. 72 103622
Javidani M, Arreguin-Zavala J, Danovitch J, Tian Y and Brochu M 2017 Additive manufacturing of AlSi10Mg alloy using direct energy deposition: microstructure and hardness characterization J. Therm. Spray Technol. 26 587–97
Chen B, Yao Y Z, Song X G, Tan C W, Cao L and Feng J C 2018 Microstructure and mechanical properties of additive manufacturing AlSi10Mg alloy using direct metal deposition Ferroelectrics 523 153–66
Men H and Fan Z 2011 Effects of solute content on grain refinement in an isothermal melt Acta Mater. 59 2704–12
Li H T, Wang Y and Fan Z 2012 Mechanisms of enhanced heterogeneous nucleation during solidification in binary Al–Mg alloys Acta Mater. 60 1528–37
Tong X C and Fang H S 1998 Al-TiC composites in situ–processed by ingot metallurgy and rapid solidification technology: part I. Microstructural evolution Metall. Mater. Trans. A 29 875–91
Qiu D, Taylor J A and Zhang M X 2010 Understanding the Co-poisoning effect of Zr and Ti on the grain refinement of cast aluminum alloys Metall. Mater. Trans. A 41 3412–21
Montero-Sistiaga M L, Mertens R, Vrancken B, Wang X B, Van Hooreweder B, Kruth J P and Van Humbeeck J 2016 Changing the alloy composition of Al7075 for better processability by selective laser melting J. Mater. Process. Technol. 238 437–45
Hebert R J 2016 Viewpoint: metallurgical aspects of powder bed metal additive manufacturing J. Mater. Sci. 51 1165–75
Kou S 2015 A criterion for cracking during solidification Acta Mater. 88 366–74
Gao Y Y, Qiu F, Geng R, Chu J G, Zhao Q L and Jiang Q C 2019 Effects of nanosized TiCp dispersion on the high-temperature tensile strength and ductility of in situ TiCp/Al-Cu-Mg-Si nanocomposites J. Alloys Compd. 774 425–33
Gao Y Y, Qiu F, Geng R, Zhao W X, Yang D L, Zuo R, Dong B X, Han X and Jiang Q C 2018 Preparation and characterization of the Al-Cu-Mg-Si-Mn composites reinforced by different surface modified SiCp Mater. Charact. 141 156–62
Gao Y Y, Qiu F, Zhao Q L and Jiang Q C 2019 A new approach for improving the elevated-temperature strength and ductility of Al–Cu–Mg–Si alloys with minor amounts of dual-phased submicron/nanosized TiB2–TiC particles Mater. Sci. Eng. A 764 138266
Li R D, Wang M B, Li Z M, Cao P, Yuan T C and Zhu H B 2020 Developing a high-strength Al-Mg-Si-Sc-Zr alloy for selective laser melting: crack-inhibiting and multiple strengthening mechanisms Acta Mater. 193 83–98
Hu J, Shi Y N, Sauvage X, Sha G and Lu K 2017 Grain boundary stability governs hardening and softening in extremely fine nanograined metals Science 355 1292–6
Zhu Z G, Ng F L, Seet H L, Lu W J, Liebscher C H, Rao Z Y, Raabe D and Mui Ling Nai S 2022 Superior mechanical properties of a selective-laser-melted AlZnMgCuScZr alloy enabled by a tunable hierarchical microstructure and dual-nanoprecipitation Mater. Today 52 90–101
Ryen Ø, Holmedal B, Nijs O, Nes E, Sjölander E and Ekström H E 2006 Strengthening mechanisms in solid solution aluminum alloys Metall. Mater. Trans. A 37 1999–2006
Seidman D N and Marquis E 2002 Precipitation strengthening at ambient and elevated temperatures of heat-treatable Al(Sc) alloys Acta Mater. 50 4021–35
Fuller C B, Seidman D N and Dunand D C 2003 Mechanical properties of Al(Sc,Zr) alloys at ambient and elevated temperatures Acta Mater. 51 4803–14
Kumar N and Mishra R S 2013 Additivity of strengthening mechanisms in ultrafine grained Al–Mg–Sc alloy Mater. Sci. Eng. A 580 175–83
Ma K K, Wen H M, Hu T, Topping T D, Isheim D, Seidman D N, Lavernia E J and Schoenung J M 2014 Mechanical behavior and strengthening mechanisms in ultrafine grain precipitation-strengthened aluminum alloy Acta Mater. 62 141–55
Sun L et al 2018 A novel ultra-high strength maraging steel with balanced ductility and creep resistance achieved by nanoscale β-NiAl and Laves phase precipitates Acta Mater. 149 285–301
Mo Y T, Wang C, Zhang S Y, Liu X, Zha M, Luan J H, Jiao Z B and Wang H Y 2022 Achieving high strength-ductility synergy through high-density coherent precipitation in twin-roll cast Al–Zn–Mg–Cu strips Mater. Sci. Eng. A 850 143592
Xu R, Li R D, Yuan T C, Zhu H B, Wang M B, Li J F, Zhang W and Cao P 2022 Laser powder bed fusion of Al–Mg–Zr alloy: microstructure, mechanical properties and dynamic precipitation Mater. Sci. Eng. A 859 144181
Sun Z Y, He B, Chen R and Wang H M 2022 Anomalous precipitation of Al3Sc dispersoids on deformation behavior of a novel Al-Cu-Li alloy fabricated by direct energy deposition Mater. Lett. 318 132207
Pu B W, Zhang X, Zhao D D, He C N, Shi C S, Liu E Z, Sha J W and Zhao N Q 2021 Achieving prominent strengthening efficiency of graphene nanosheets in Al matrix composites by hybrid deformation Carbon 183 530–45
Xiao Y K, Yang Q, Bian Z Y, Chen H, Wu Y, Lian Q, Chen Z and Wang H W 2021 Microstructure, heat treatment and mechanical properties of TiB2/Al–7Si–Cu–Mg alloy fabricated by selective laser melting Mater. Sci. Eng. A 809 140951
Liu T S, Qiu F, Yang H Y, Tan C L, Dong B X, Xie J F, Shu S L, Jiang Q C and Zhang L C 2022 Versatility of trace nano-TiC–TiB2 in collaborative control of solidification-rolling-welding microstructural evolution in Al–Mg–Si alloy for enhanced properties Mater. Sci. Eng. A 851 143661
Nardone V C and Prewo K M 1986 On the strength of discontinuous silicon carbide reinforced aluminum composites Scr. Metall. 20 43–48
Luo S H, Zhou L C, Nie X F, Li Y H and He W F 2019 The compound process of laser shock peening and vibratory finishing and its effect on fatigue strength of Ti-3.5Mo-6.5Al-1.5Zr-0.25Si titanium alloy J. Alloys Compd. 783 828–35
Ballard P, Fournier J, Fabbro R and Frelat J 1991 Residual stresses induced by laser-shocks J. Phys. IV 1 C3-487–94
Liu D H, Wu D J, Wang R Z, Shi J G, Niu F Y and Ma G Y 2022 Formation mechanism of Al-Zn-Mg-Cu alloy fabricated by laser-arc hybrid additive manufacturing: microstructure evaluation and mechanical properties Addit. Manuf. 50 102554
Gao H J and Huang Y G 2003 Geometrically necessary dislocation and size-dependent plasticity Scr. Mater. 48 113–8
Huang Y and Langdon T G 2013 Advances in ultrafine-grained materials Mater. Today 16 85–93
Chen L Q, Bi G J, Yao X L, Tan C L, Su J L, Ng N P H, Chew Y, Liu K and Ki Moon S 2023 Multisensor fusion-based digital twin for localized quality prediction in robotic laser-directed energy deposition Robot. Comput. 84 102581
Shi T, Sun J Y, Li J H, Qian G A and Hong Y S 2023 Machine learning based very-high-cycle fatigue life prediction of AlSi10Mg alloy fabricated by selective laser melting Int. J. Fatigue 171 107585
Todaro C J, Easton M A, Qiu D, Zhang D, Bermingham M J, Lui E W, Brandt M, Stjohn D H and Qian M 2020 Grain structure control during metal 3D printing by high-intensity ultrasound Nat. Commun. 11 142
Lalegani Dezaki M, Serjouei A, Zolfagharian A, Fotouhi M, Moradi M, Ariffin M K A and Bodaghi M 2022 A review on additive/subtractive hybrid manufacturing of directed energy deposition (DED) process Adv. Powder Mater. 1 100054
Zhao K, Gao T, Yang H B, Hu K Q, Liu G L, Sun Q Q, Nie J F and Liu X F 2021 Enhanced grain refinement and mechanical properties of a high–strength Al–Zn–Mg–Cu–Zr alloy induced by TiC nano–particles Mater. Sci. Eng. A 806 140852
Islam N, Huang W J and Zhuang H L 2018 Machine learning for phase selection in multi-principal element alloys Comput. Mater. Sci. 150 230–5
Zou C X et al 2021 Integrating data mining and machine learning to discover high-strength ductile titanium alloys Acta Mater. 202 211–21
Rappaz M, Jacot A and Boettinger W J 2003 Last-stage solidification of alloys: theoretical model of dendrite-arm and grain coalescence Metall. Mater. Trans. A 34 467–79
Rappaz M, Drezet J M and Gremaud M 1999 A new hot-tearing criterion Metall. Mater. Trans. A 30 449–55
Loutas T H, Kliafa P M, Sotiriadis G and Kostopoulos V 2019 Investigation of the effect of green laser pre-treatment of aluminum alloys through a design-of-experiments approach Surf. Coat. Technol. 375 370–82
Hossain M S and Taheri H 2021 In-situ process monitoring for metal additive manufacturing through acoustic techniques using wavelet and convolutional neural network (CNN) Int. J. Adv. Manuf. Technol. 116 3473–88
Li M Y, Du Z J, Ma X X, Dong W and Gao Y Z 2021 A robot hand-eye calibration method of line laser sensor based on 3D reconstruction Robot. Comput. 71 102136
Li C G, Liu C M, Li S, Zhang Z, Zeng M, Wang F F, Wang J Q and Guo Y J 2019 Numerical simulation of thermal evolution and solidification behavior of laser cladding AlSiTiNi composite coatings Coatings 9 391
Caiazzo F, Alfieri V and Bolelli G 2022 Residual stress in laser-based directed energy deposition of aluminum alloy 2024: simulation and validation Int. J. Adv. Manuf. Technol. 118 1197–211