<p>Laser-directed energy deposition (L-DED) is a key additive manufacturing technology with extensive applications in aerospace, automotive, and biomedical industries due to its ability to fabricate complex geometries and repair high-value components. However, optimizing material strength, toughness, and process efficiency remains a critical challenge due to issues such as microstructural anisotropy, residual stress, and defect formation. This review presents a comprehensive multidimensional strategy for enhancing the performance of L-DED manufactured materials by integrating material selection, process control, structural optimization, and advanced manufacturing technologies. It evaluates the mechanical properties of commonly used materials and analyzes the influence of laser power, scanning strategies, and powder feed rate on melt pool behavior, grain morphology, and defects. Additionally, it explores novel structures and technological advancements aimed at improving microstructural uniformity and reducing porosity. The review also introduces an integrated optimization framework that combines AI-driven process control, real-time monitoring, and sustainable manufacturing techniques. By addressing these key challenges, this study contributes to the development of high-strength, defect-free, and industrially viable L-DED technologies, facilitating their broader adoption in high-performance engineering applications.</p>

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Multidimensional Optimization Strategies in Laser-Directed Energy Deposition: Enhancing Material Strength, Toughness, and Process Efficiency

  • Yufeng Zhao,
  • Jun Wei,
  • Yinfang Jiang,
  • Guang Ji

摘要

Laser-directed energy deposition (L-DED) is a key additive manufacturing technology with extensive applications in aerospace, automotive, and biomedical industries due to its ability to fabricate complex geometries and repair high-value components. However, optimizing material strength, toughness, and process efficiency remains a critical challenge due to issues such as microstructural anisotropy, residual stress, and defect formation. This review presents a comprehensive multidimensional strategy for enhancing the performance of L-DED manufactured materials by integrating material selection, process control, structural optimization, and advanced manufacturing technologies. It evaluates the mechanical properties of commonly used materials and analyzes the influence of laser power, scanning strategies, and powder feed rate on melt pool behavior, grain morphology, and defects. Additionally, it explores novel structures and technological advancements aimed at improving microstructural uniformity and reducing porosity. The review also introduces an integrated optimization framework that combines AI-driven process control, real-time monitoring, and sustainable manufacturing techniques. By addressing these key challenges, this study contributes to the development of high-strength, defect-free, and industrially viable L-DED technologies, facilitating their broader adoption in high-performance engineering applications.