University of Oulu

Abd-Elaziem, W., Elkatatny, S., Abd-Elaziem, A.-E., Khedr, M., Abd El-baky, M. A., Hassan, M. A., Abu-Okail, M., Mohammed, M., Järvenpää, A., Allam, T., & Hamada, A. (2022). On the current research progress of metallic materials fabricated by laser powder bed fusion process: A review. Journal of Materials Research and Technology, 20, 681–707.

On the current research progress of metallic materials fabricated by laser powder bed fusion process : a review

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Author: Abd-Elaziem, Walaa1; Elkatatny, Sally2; Abd-Elaziem, Abd-Elrahim3;
Organizations: 1Department of Mechanical Design and Production Engineering, Faculty of Engineering, Zagazig University, P.O. Box 44519, Egypt
2Mechanical Engineering Department, Faculty of Engineering, Suez Canal University, Ismailia 41522, Egypt
3Mechatronics Engineering Department, German University in Cairo (GUC), New Cairo City 11865, Egypt
4Mechanical Engineering Department, Faculty of Engineering at Shoubra, Benha University, Cairo 11629, Egypt
5Mechanical Department, Faculty of Technology and Education, Sohag University, Sohag 82524, Egypt
6Manufacturing Engineering and Production Technology Department, Modern Academy for Engineering and Technology, Cairo, P.O. Box 11571, Egypt
7Mechanical Department, Faculty of Technology and Education, Beni_Suef University, Beni_Suef 62521, Egypt
8Kerttu Saalasti Institute, Future Manufacturing Technologies (FMT) Unit, University of Oulu, Pajatie 5, 85500, Nivala, Finland
9Institute of Energy and Climate Research: Structure and Function of Materials (IEK-2), Forschungszentrum Jülich GmbH, 52425, Jülich, Germany
Format: article
Version: published version
Access: open
Online Access: PDF Full Text (PDF, 7.4 MB)
Persistent link:
Language: English
Published: Elsevier, 2022
Publish Date: 2023-02-02


Laser powder bed fusion (LPBF) is the most common metal additive manufacturing technique. Following pre-programmed designs, it employs a high-power density laser source to melt pre-alloyed or mixed powders layer by layer, allowing for complex metallic component fabrication.

This technique has recently been utilised to produce superior, near-full-density three-dimensional functional parts for various industrial applications. As the LPBF technology matures, ongoing research is being conducted to increase its viability as a sustainable solution in achieving digital transformation in metallic materials and qualifying new metallic materials for digital products. This review focuses on recent developments in the LPBF technique in terms of process parameters, defects, microstructure evolution, related metallurgical phenomena, and microselective laser melting processing for miniaturised part production. First, considerable attention is given to the related parameters that affect the LPBF process, that is, powder-related and laser-related properties. Second, the metallurgical imperfections related to the LPBF products are described in terms of their types, formation mechanisms, and suppression strategies for these defects. Third, the solidification behaviour, phase transformation, and precipitation during the LPBF processing were systematically investigated. Fourth, the materials implemented in microselective laser melting for three-dimensional microfeature production on various metals are summarised. Finally, the results from this review are summarized, and future research addressing existing difficulties and promoting technical advancements are recommended.

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Series: Journal of materials research and technology
ISSN: 2238-7854
ISSN-E: 2214-0697
ISSN-L: 2238-7854
Volume: 20
Pages: 681 - 707
DOI: 10.1016/j.jmrt.2022.07.085
Type of Publication: A2 Review article in a scientific journal
Field of Science: 216 Materials engineering
Copyright information: © 2022 The Author(s). This is an open access article under the CC BY-NC-ND license (