Aluminum Parts Fabricated by Laser-Foil-Printing Additive Manufacturing: Processing, Microstructure, and Mechanical Properties Academic Article uri icon


  • Fabrication of dense aluminum (Al-1100) parts (>99.3% of relative density) by our recently developed laser-foil-printing (LFP) additive manufacturing method was investigated as described in this paper. This was achieved by using a laser energy density of 7.0 MW/cm2 to stabilize the melt pool formation and create sufficient penetration depth with 300 μm thickness foil. The highest yield strength (YS) and ultimate tensile strength (UTS) in the LFP-fabricated samples reached 111 ± 8 MPa and 128 ± 3 MPa, respectively, along the laser scanning direction. These samples exhibited greater tensile strength but less ductility compared to annealed Al-1100 samples. Fractographic analysis showed elongated gas pores in the tensile test samples. Strong crystallographic texturing along the solidification direction and dense subgrain boundaries in the LFP-fabricated samples were observed by using the electron backscattered diffraction (EBSD) technique.

published proceedings

  • Materials

author list (cited authors)

  • Hung, C., Li, Y., Sutton, A., Chen, W., Gong, X., Pan, H., Tsai, H., & Leu, M. C.

citation count

  • 4

complete list of authors

  • Hung, Chia-Hung||Li, Yingqi||Sutton, Austin||Chen, Wei-Ting||Gong, Xiangtao||Pan, Heng||Tsai, Hai-Lung||Leu, Ming C

publication date

  • January 2020