A Review Study on Metal Powder Materials and Processing Parameters in Laser Metal Deposition

Laser additive manufacturing is a layer-by-layer process that offers flexibility in manufacturing complex shapes without dedicated tools. It is also used for repairing high-cost parts, making it attractive to various industries. This paper reviews the use of metal powder materials and process parameters in Direct Energy Deposition, with a focus on Laser Metal Deposition, but also covers other methods with similar approaches. The paper starts by describing the metal powder manufacturing and characterization processes for better understanding of the raw materials. Next, it provides information on the most commonly used machines on the market. Then, a number of reported studies are analyzed to determine the possible range of working parameters and feasible results. Finally, a recommended range of processing parameters is provided based on the reported studies to help manufacturers select the best options.