Impact of process parameters on mechanical and microstructure properties of aluminum alloys and aluminum matrix composites processed by powder-based additive manufacturing

This review provides a critical synthesis of aluminum (Al) alloys and aluminum matrix composites (AMCs) fabricated utilizing powder-based additive manufacturing (AM) techniques, with a focus on Powder Bed Fusion (PBF) and Direct Energy Deposition (DED). The work systematically examines how key process parameters such as laser power, scan speed, and energy density—influence microstructural topographies like porosity, grain morphology, and reinforcement distribution, which in turn govern mechanical performance. AlSi10Mg is identified as a widely used AM alloy due to its favorable mechanical and thermal properties. The addition of ceramic reinforcements such as TiB₂, SiC, and Ta nanoparticles enhances strength and grain refinement, although challenges remain in achieving uniform dispersion and minimizing interfacial defects. Powder characteristics, including particle size distribution and morphology, are shown to significantly affect packing density, melt pool behavior, and final part quality. Post-processing methods, including heat treatment and hot isostatic pressing (HIP), are reviewed for their roles in improving ductility and relieving residual stress. However, their effectiveness varies between PBF and DED due to differences in thermal profiles and solidification rates. Hybrid AM approaches and AI-driven process optimization are highlighted as emerging solutions for achieving more consistent microstructural control and defect mitigation. Despite advancements, gaps persist in understanding fatigue behavior, creep resistance, impact strength, and vibration tolerance in AMCs. This review addresses these limitations and introduces a structured framework linking process parameters to final properties, supporting the development of reproducible, high-performance aluminum-based AM components for industrial applications.