Research Information System
JOM, vol.77, no.11, pp.8895-8916, 2025 (SCI-Expanded)
The use of aluminum alloy parts in the automotive and aviation industries is increasing due to the advantages, such as design freedom, reduced weight, and near-zero waste processes, provided by additive manufacturing (AM). However, AM production of aluminum alloys with high strength remains challenging due to the very rapid solidification environment, which promotes defects such as porosity and hot cracking. This review systematically examines the sources of these defects from feedstock properties to process-induced issues. Feedstock-related defects can lead to porosities. Additionally, process-related factors like energy density and thermal gradients play a significant role in crack formation and surface quality. To address these challenges, alloy modification has become an important strategy. Additions of elements such as Zr, Ti, Sc, and Si have been shown to refine grain structures, promote equiaxed solidification, reduce hot cracking susceptibility, and significantly enhance mechanical properties, with reported improvements in tensile strength and ductility. The article further emphasizes the necessity of process optimization and scanning strategies tailored to the composition and shape of alloys, which enable the control of thermal gradients. Overall, this review emphasizes the need for integrated approaches involving process optimization and alloy design to make high-performance aluminum alloys available for AM production.