Additively Manufactured Aluminum-Lithium Alloys—Advances, Challenges, and Future Directions

Aluminum-lithium alloys are extensively used across various industries due to their exceptional strength-to-weight ratio, excellent fatigue/corrosion resistance and good thermal stability. These attributes, combined with improved weldability and ease of fabrication, make them ideal for lightweight engineering applications in sectors such as aerospace, automotive, and defense. Additive manufacturing (AM) offers unique opportunities to fully leverage the potential of aluminum-lithium alloys by enabling the fabrication of complex geometries, minimizing material waste, and supporting on-demand production. This paper explores the significance of lightweight materials, traces the evolution of aluminum-lithium alloys and provides a comprehensive overview of their AM. It discusses the properties and real-world applications of these alloys and examines various AM techniques employed in their processing. Key advancements in the AM of aluminum-lithium alloys are reviewed, including novel alloy formulations, development of high-lithium-content variants, microstructural and mechanical property enhancements through heat treatment, defect mitigation strategies, and surface treatment methods for performance improvement. Challenges associated with the AM of aluminum-lithium alloys are also addressed. The paper concludes by outlining future research directions and technological developments aimed at advancing AM processes for next-generation lightweight engineering solutions.