The high thermal conductivity and melt pool optical reflectivity associated with aluminum alloys can pose significant challenges for direct-metal SFF processes. The use of SFF processes to produce aluminum parts is often not cost effective relative to CNC machining for simple geometries. However, the use of SFF techniques for aluminum alloys is justified for some applications such as aerospace forgings or high surface area heat exchangers. This paper describes recent progress in processing aluminum alloys using the Electron Beam Melting process. Structure and properties will be discussed, as well challenges associated with high vapor pressure alloying elements such as zinc and magnesium.
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