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<p>Aluminum alloys are very useful due to their lightweight and high-performance qualities, but they provide considerable hurdles for directed energy deposition. Due to the high reflectivity of aluminum, infrared lasers exacerbate these concerns. This review paper looks at recent advances in addressing these problems. The use of blue lasers has emerged as a pioneering development, allowing for better absorption rates and more efficient powder melting with lower energy inputs. Compared with traditional near-infrared sources around 1060&#xa0;nm, blue at about 450&#xa0;nm reaches full melting at lower power density; for example, at 900&#xa0;W and 4&#xa0;mm/s a blue laser produced an approximately 2.5&#xa0;mm-wide and 0.35&#xa0;mm-deep melt pool in AlSi10Mg, while a near-infrared laser did not fully melt under the same settings. Optimum procedures such as substrate preheating, intermittent process flow, bi-directional scanning, and multi-layer offset stacking are methods that improve deposition quality and mechanical performance, attaining tensile properties comparable to as-cast alloys. In situ alloy design, particle reinforcement, field-assisted procedures, and precise emissivity control have proven useful in improving heat management and deposit stability. This review explains how process parameters, alloy composition, and microstructure interact, and summarizes guidance for scalable, high-performance aluminum alloy applications that aim for strong structural integrity.</p>

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Surface Reflectivity of Aluminum Alloys in Direct Energy Deposition: A Review

  • 期刊论文

  • 发表日期：

    2026年1月22日

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  • Nikunj Patel,
  • Gaurav Mittal,
  • Kedar Badheka

摘要

Aluminum alloys are very useful due to their lightweight and high-performance qualities, but they provide considerable hurdles for directed energy deposition. Due to the high reflectivity of aluminum, infrared lasers exacerbate these concerns. This review paper looks at recent advances in addressing these problems. The use of blue lasers has emerged as a pioneering development, allowing for better absorption rates and more efficient powder melting with lower energy inputs. Compared with traditional near-infrared sources around 1060 nm, blue at about 450 nm reaches full melting at lower power density; for example, at 900 W and 4 mm/s a blue laser produced an approximately 2.5 mm-wide and 0.35 mm-deep melt pool in AlSi10Mg, while a near-infrared laser did not fully melt under the same settings. Optimum procedures such as substrate preheating, intermittent process flow, bi-directional scanning, and multi-layer offset stacking are methods that improve deposition quality and mechanical performance, attaining tensile properties comparable to as-cast alloys. In situ alloy design, particle reinforcement, field-assisted procedures, and precise emissivity control have proven useful in improving heat management and deposit stability. This review explains how process parameters, alloy composition, and microstructure interact, and summarizes guidance for scalable, high-performance aluminum alloy applications that aim for strong structural integrity.