<p>Carbon nanotubes (CNTs) present a transformative potential for enhancing the properties of metal components fabricated via laser powder bed fusion additive manufacturing (LPBF-AM). This comprehensive review delves into the integration of CNTs with various metallic powders for the LPBF-AM process and the resulting enhancements in mechanical, thermal, and electrical properties. The review begins with an overview of LPBF-AM technology, followed by a discussion of CNT structures and properties, providing the necessary background. Current research on incorporating CNTs into metals such as titanium, copper, stainless steel, nickel, and aluminum for LPBF-AM is explored. These studies demonstrate improvements in hardness, strength, laser absorptivity, and defect reduction, primarily attributed to in situ carbide formation and the hindrance of dislocation movement. However, maximizing the potential of CNTs in this context requires overcoming specific challenges, such as ensuring homogeneous dispersion, enhancing interfacial bonding, and maintaining high-temperature stability during the LPBF process. This review also addresses these challenges, focusing on research gaps, such as porosity/defect control, laser–matter interactions, and the relationship between microstructure and properties. Finally, emerging application domains in aerospace, automotive, biomedical, and electronic systems are discussed, positioning CNT-reinforced LPBF-AM as a frontier for next-generation multifunctional materials and advanced manufacturing technologies. These applications are driven by the exceptional mechanical strength, thermal conductivity, and electrical conductivity of CNT/metal composites. Ultimately, the synergistic integration of CNTs into LPBF processes paves the way for the development of multifunctional components with superior durability, efficiency, and sustainability, unlocking new possibilities across critical additive manufacturing industries.</p>

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Synergistic integration of carbon nanotubes in laser powder bed fusion: advancing multifunctional metal additive manufacturing

  • Muslim Al-Mahmood,
  • Said Sakhi,
  • Wael Abuzaid,
  • Maen Alkhader,
  • Ali S. Alnaser

摘要

Carbon nanotubes (CNTs) present a transformative potential for enhancing the properties of metal components fabricated via laser powder bed fusion additive manufacturing (LPBF-AM). This comprehensive review delves into the integration of CNTs with various metallic powders for the LPBF-AM process and the resulting enhancements in mechanical, thermal, and electrical properties. The review begins with an overview of LPBF-AM technology, followed by a discussion of CNT structures and properties, providing the necessary background. Current research on incorporating CNTs into metals such as titanium, copper, stainless steel, nickel, and aluminum for LPBF-AM is explored. These studies demonstrate improvements in hardness, strength, laser absorptivity, and defect reduction, primarily attributed to in situ carbide formation and the hindrance of dislocation movement. However, maximizing the potential of CNTs in this context requires overcoming specific challenges, such as ensuring homogeneous dispersion, enhancing interfacial bonding, and maintaining high-temperature stability during the LPBF process. This review also addresses these challenges, focusing on research gaps, such as porosity/defect control, laser–matter interactions, and the relationship between microstructure and properties. Finally, emerging application domains in aerospace, automotive, biomedical, and electronic systems are discussed, positioning CNT-reinforced LPBF-AM as a frontier for next-generation multifunctional materials and advanced manufacturing technologies. These applications are driven by the exceptional mechanical strength, thermal conductivity, and electrical conductivity of CNT/metal composites. Ultimately, the synergistic integration of CNTs into LPBF processes paves the way for the development of multifunctional components with superior durability, efficiency, and sustainability, unlocking new possibilities across critical additive manufacturing industries.