Research Progress on Laser Cladding Aluminum Alloy Coatings

KANG Jianjian

doi:10.3969/j.issn.1674-6457.2026.09.015

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (9) : 143-158. DOI: 10.3969/j.issn.1674-6457.2026.09.015

Additive Manufacturing

Research Progress on Laser Cladding Aluminum Alloy Coatings

KANG Jianjian

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Abstract

Aluminum alloys are widely used in aerospace, automotive manufacturing, and energy equipment due to their light weight, high specific strength, and excellent thermal and electrical conductivity. However, their poor surface wear resistance, corrosion resistance, and high-temperature stability limit their long-term service in harsh environments. Laser cladding technology, with its high energy density, rapid solidification, and excellent metallurgical bonding properties, can be used to prepare dense and firmly bonded functional coatings on the surface of aluminum alloys, effectively improving their comprehensive performance. This article systematically reviews the research progress of laser cladding aluminum alloy coatings, including basic principles and key influencing factors, with a focus on traditional material systems such as nickel-based, copper-based, iron-based, ceramic, and metal ceramic composite coatings, and further discusses the development status of new coatings such as high-entropy alloys, gradient materials, and amorphous alloys. At the same time, the influence mechanisms of different process parameters on the microstructure, mechanical properties, and corrosion resistance of the coatings are analyzed. Although laser cladding has achieved significant progress in improving the surface properties of aluminum alloys, it still faces several key challenges: such as insufficient heat input due to high reflectivity and high thermal conductivity, cracks and pores caused by unstable molten pools, uneven bonding caused by interface reaction layers, and the difficulty in maintaining consistent cladding quality on large areas and complex curved surfaces. Future research should focus on material system innovation, process parameter optimization, and multi-physical field coupling control, so as to achieve high-performance, low-defect, and highly reliable aluminum alloy cladding coatings, and meet the application requirements of high-end equipment and extreme service environments.

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laser cladding / aluminum alloy / coating / microstructure / corrosion resistance

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KANG Jianjian. Research Progress on Laser Cladding Aluminum Alloy Coatings[J]. Journal of Netshape Forming Engineering. 2026, 18(9): 143-158 https://doi.org/10.3969/j.issn.1674-6457.2026.09.015

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