AccScience Publishing / MSAM / Volume 5 / Issue 1 / DOI: 10.36922/MSAM025240051
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REVIEW ARTICLE

Laser additive manufacturing of nickel-based superalloys: A review

Yunlong Hu1* ,  Zihong Wang1* ,  Qiang Zhang1 ,  Shan Li1 ,  Xin Zhang2 ,  Weidong Huang2
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1 Department of Structural Materials Research, Suzhou Laboratory, Suzhou, Jiangsu, China
2 State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an, Shaanxi, China
MSAM 2026, 5(1), 025240051 https://doi.org/10.36922/MSAM025240051
Received: 14 June 2025 | Accepted: 11 August 2025 | Published online: 31 October 2025
(This article belongs to the Special Issue Additive Manufacturing of Materials for Extreme Environments)
© 2025 by the Author(s).. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( https://creativecommons.org/licenses/by/4.0/ )
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Abstract

Nickel-based superalloys are critical materials for high-temperature components in core equipment, such as aerospace engines and gas turbines. In recent years, with the rapid advancement of metal additive manufacturing (AM) technologies, the fabrication of complex geometries using nickel-based superalloys has been successfully applied in modern engines and gas turbines. These components demonstrate significant advantages in integration, weight reduction, multifunctionality, and performance enhancement. However, due to the complex alloy composition and multiphase microstructure of nickel-based superalloys, the AM process is accompanied by intricate phase transformations and high thermal stresses. This often leads to defects, such as hot cracking—particularly in the vicinity of the molten pool. In addition, the rapid non-equilibrium solidification and repeated thermal cycles from layer-by-layer deposition result in complex microstructural evolution and phase transformations during both solidification and subsequent solid-state reactions. These factors significantly influence the strengthening and toughening behavior of the superalloys. Consequently, the comprehensive mechanical properties of additively manufactured nickel-based superalloys still lag behind those of their traditionally forged counterparts. This article reviews recent domestic and international research progress on the mechanisms of crack formation and control strategies in AM of nickel-based superalloys, as well as the evolution of microstructure and the associated strengthening and toughening mechanisms. Furthermore, it discusses the design of nickel-based superalloys tailored specifically for AM, and offers insights and future perspectives on the development of advanced strengthening strategies and alloy design methodologies for AM applications.

Graphical abstract
Keywords
Additive manufacturing
Nickel-based superalloy
Cracking mechanism
Microstructural evolution
Strengthening mechanism
Alloy design
Funding
This work was supported by the Advanced Materials- National Science and Technology Major Project (Grant No. 2024ZD0601000), National Natural Science Foundation of China (Grant No. 52105344), Natural Science Foundation of Guangdong Province (Grant No. 2021A1515010942), and Guangzhou Basic and Applied Basic Research (Grant No. 202201010365).
Conflict of interest
The authors declare no financial or personal relationships with other people or organizations that can inappropriately influence the present work. There is no professional or other personal interest of any nature or kind in any product, service, or company that could be construed as influencing the work presented in, or the review of, the present article.
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Materials Science in Additive Manufacturing, Electronic ISSN: 2810-9635 Published by AccScience Publishing
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