| Abstract Scope |
This presentation establishes methodology for additive manufacturing of aluminum alloys using a Blue Laser Wire Direct Energy Deposition (DED) system, emphasizing the critical role of process parameter optimization. Leveraging the enhanced absorption efficiency of blue lasers with aluminum, the study investigates how energy density, modulated through laser power, scan speed, and wire feed rate, affects deposition quality, porosity, build density, and the resulting microstructural and mechanical properties. Both conventional aluminum alloys (e.g., 4043, 6061, 7075) and emerging compositions tailored for AM were evaluated. Results reveal key processing windows that minimize defects such as lack of fusion, spatter, and porosity while enhancing interlayer bonding and grain refinement. The talk will highlight both the technical successes and unexpected challenges encountered, including lessons learned regarding melt pool control, substrate preparation, and the complex thermal behavior of aluminum during deposition. These insights inform future alloy design and processing strategies for high-performance aluminum AM components. |