Additive Manufacturingof SiC/Al Composites: Current Research and Future Trends

Aluminum matrix composites reinforced with silicon carbide (SiCp/Al) have been extensively applied in aerospace, transportation, defense, and electronic packaging industries owing to their superior strength-to-weight ratio, thermal stability, and wear resistance. However, conventional manufacturing methods for SiCp/Al composites face significant challenges due to the inherent characteristics of the material, such as the high hardness and brittleness of ceramic reinforcements. Issues including low material utilization, prolonged production cycles (exceeding 45 days for complex components), and inconsistent product quality severely limit their industrial application. Additive manufacturing (AM) technology, recognized as a sustainable manufacturing paradigm, offers innovative solutions through its capacity for near-net-shape fabrication of complex geometries with minimal material waste and reduced tooling requirements. This review systematically analyzes the current research progress and technical barriers in selective laser melting (SLM) of SiCp/Al composites, with particular emphasis on unresolved issues such as inhomogeneous particle distribution . Furthermore, it critically examines potential applications in lightweight aerospace components and thermal management systems, while discussing emerging strategies like gradient interface design and hybrid AM processes to address existing challenges.