Nickel-based superalloy matrix composites fabricated by laser additive manufacturing: A critical review of recent advances and overcoming challenges

Laser additive manufacturing (LAM) has become a crucial method for fabricating metal and alloy parts with complex geometries and outstanding performance, particularly nickel-based superalloys, which are celebrated for their exceptional high-temperature capabilities, making them indispensable in demanding applications such as aerospace engines, industrial turbines and nuclear reactors, etc. Recent advancements have centered on integrating reinforcement materials during LAM to enhance material properties. To lay a solid foundation for the LAM process of nickel-based superalloy matrix composites (NSMCs), this comprehensive review delves into recent progress in their fabrication and analysis. It begins by examining various LAM technologies and offering crucial insights into nickel-based superalloys. Subsequently, it discusses different composite types based on the added materials, emphasizing in detail the functions of these introduced materials, including their role in cracking mitigation and improvements in mechanical and surface properties. Finally, the review identifies challenges and offers perspectives to guide future research. These insights are designed to be valuable for researchers and engineers across diverse fields, as the crack-prevention techniques and strengthening principles outlined here are also applicable to other alloy systems. © 2025 Elsevier B.V.