Arc-Based Directed Energy Deposition (DED-Arc) of 7xxx Series Al-Zn-Mg-Cu Alloys: A Review
(2026) Progress in Additive Manufacturing — (2026)
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Review on DED-Arc of 7xxx series Al Alloys.pdf
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- Abstract
- Additive manufacturing (AM) of aluminium alloys has gained increasing relevance in high-performance sectors such as aerospace, defence and automotive. However, processing Al-Zn-Mg-Cu alloys (7xxx series) by fusion-based techniques remains challenging due to hot cracking, porosity, elemental vaporisation and oxide formation. Arc-based directed energy deposition (DED-Arc), also known as wire-arc additive manufacturing (WAAM), has recently emerged as a promising approach to overcome some of these limitations, particularly for large structural components. This review provides a comprehensive overview of recent progress on DED-Arc of 7xxx series alloys, with emphasis on microstructural evolution, defect formation mechanisms and resulting mechanical properties. Reported strategies to mitigate imperfections include advanced arc modes, hybrid laser-arc or ultrasonic assistance, active cooling, interlayer deformation and inoculant additions such as TiC, TiN, Zr and Sc. Studies also demonstrate the influence of post-processing heat treatments in enhancing mechanical strength and fatigue resistance. Research activity in this field has increased significantly in recent years, although investigations remain limited compared to other alloys. Addressing current challenges through 2 process optimisation, alloy design and qualification efforts will be critical to establish DED-Arc as an industrially viable route for high-performance aluminium components.
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Citations
Oliveira, I., Gomes Nunes Silva, R., Verlinde, W., Faes, K., De Waele, W., Lezaack, M. B., & Simar, A. (2026). Arc-Based Directed Energy Deposition (DED-Arc) of 7xxx Series Al-Zn-Mg-Cu Alloys: A Review. Progress in Additive Manufacturing. Submitted. https://doi.org/10.1007/s40964-026-01683-y (Original work published 2026)