Review on Laser Powder Injection Additive Manufacturing of Novel Alloys and Composites

In this paper, recent research and progress associated with development of alloys and composites using LENS (R) are reviewed. The microstructure of novel materials can be tailored by controlling both composition and process parameters. For process control, closed-loop diagnostics and controls such as in-situ molten pool sensor and Z-height control subsystems are utilized, while the thermal behavior measurement with thermal imaging methods and numerical simulation are also investigated. The existing problems with residual stress and porosity in deposited materials are discussed.