Abstract:
Laser additive manufacturing (LAM) offers high design freedom, mold-free fabrication, and near-net-shape forming. It is therefore an important approach for fabricating complex, high-performance ceramic components. However, ceramics are intrinsically brittle. In addition, rapid melting and solidification generate high thermal gradients and thermal stresses. As a result, LAM-fabricated components are prone to microcrack initiation and even macroscopic cracking, which compromises their structural integrity and service reliability. To address this challenge, materials design has become an important strategy for tailoring microstructures, suppressing crack formation and improving mechanical performance. This review summarizes three representative materials design methods for ceramic LAM, including eutectic design, grain/solidification microstructure refinement, and dispersed particle reinforcement. Their effects on solidification microstructure evolution, interface control and defects suppression are discussed. Finally, the current challenges and future research directions in this field are outlined to support the development of high-performance ceramic material systems and the fabrication of complex components.