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NUAA Develops Ultrafast Laser-Assisted In Situ Hybrid LPBF to Reduce Surface Roughness and Enhance Strength
2026-06-10
A team from Nanjing University of Aeronautics and Astronautics (NUAA) has developed an ultrafast laser-assisted in situ hybrid manufacturing process (integrating continuous-wave and ultrafast lasers) to address powder adhesion and slag defects on the sidewalls of high-strength aluminum alloys formed by LPBF. Compared with conventional LPBF, the process reduces side surface roughness from 53.7 μm to 5.2 μm—a 90% decrease—while eliminating balling and powder adhesion. The melt pool transitions from keyhole mode to conduction mode, reducing porosity. The Al₃(Sc,Zr) nanoprecipitates coarsen from 20 nm to 50 nm, and tensile strength increases from approximately 402 MPa to 515 MPa—a 28% improvement—with no significant change in residual stress. This research provides a new pathway for high-precision integrated manufacturing of complex aerospace structures.
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南航开发超快激光辅助LPBF原位混合制造，降低表面粗糙度并提升强度
南京航空航天大学团队针对LPBF成形高强铝合金侧壁粉末粘附与熔渣缺陷问题，开发了超快激光辅助原位混合制造工艺（连续激光+超快激光集成）。与传统LPBF相比，该工艺将侧表面粗糙度从53.7 μm降至5.2 μm，降幅90%，消除球化与粉末粘附；熔池从匙孔模式转为传导模式，孔隙率降低；Al₃(Sc,Zr)纳米析出相从20 nm粗化至50 nm，抗拉强度从约402 MPa提升至515 MPa，增幅28%，且残余应力无明显变化。该研究为航空航天复杂结构的高精度一体化制造提供了新路径。