Additively Manufactured of Aluminum Alloy: Processes, Properties, and Applications

This paper reviews recent advances in additive manufacturing (AM) of aluminum alloys and proposes an integrated framework of materials, processes, microstructure, properties, and applications. Focusing on Laser Powder Bed Fusion (L-PBF) and Directed Energy Deposition (DED), it summarizes the major challenges of aluminum alloy AM, including hot cracking, porosity, and anisotropy, together with corresponding optimization strategies. The paper particularly highlights three additive manufacturing-specific alloy systems—Sc/Zr microalloyed, heat-resistant eutectic, and transition-metal-strengthened aluminum alloys—and clarifies their composition design and strengthening mechanisms. Finally, future trends in intelligent manufacturing, integrated alloy process design, and green development are discussed, emphasizing the importance of interdisciplinary integration for large-scale industrial applications.