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PublicationLaser Directed Energy Deposition of an Almgsczr-Alloy in High-Speed Process Regimes( 2022-05)Aluminum-magnesium-scandium-zirconium (AlMgScZr) alloys require rapid cooling conditions to ensure that high solute supersaturation is obtained to exploit the material's potential of precipitation hardening. While AlMgScZr alloys have been shown to be successfully applied in laser powder bed fusion (LPBF) processes for additive manufacturing, there have been little research in laser directed energy deposition (DED). The performance of DED processed parts only reached about 60% of that of LPBF processed parts. In view of breaking through the limitation associated with the process conditions of conventional DED, this work demonstrates the DED of AlMgScZr alloys in high-speed process regimes and elucidates the mechanism of enhancing the hardness and tensile strength of AlMgScZr alloys by increasing the cooling rate by one to two orders of magnitudes during the process as well as reducing the track overlapping and the porosity of the specimens. A max. average hardness of nearly 150 HV0.1 and a max. tensile strength of 407 MPa are obtained by using an energy per unit length of 5400 J/m and a powder feed rate per unit length of 0.25 g/m.