Al-Cu-Mn-Mg alloys containing Zr were produced via selective laser melting (SLM). The processing parameters were analyzed via an orthogonal experiment, and the microstructure and mechanical properties of the specimens were investigated. The results showed that the laser power and scanning speed were the main factors affecting the density and hardness of the specimens. The optimal parameters for the SLM processing of Al-Cu-Mn-Mg alloy were a laser power of 300 W, scanning speed of 1100 mm/s, and hatch spacing of 0.12 mm. The microstructure of the specimen was made of fine equiaxed grains and columnar grains, and Al₂Cu precipitates were found in the as-printed alloy. The alloy was isotropic, and the hardness was around 100 HV. The tensile and yield strength of the alloy were 361 MPa and 266 MPa, and the elongation was 5.4%. The superior mechanical properties can be attributed to the synergy effect of the strengthening of the grain boundary, solid solution, and precipitation.

This study systematically investigated the effects of selective laser melting (SLM) process parameters on the forming quality and microstructure of FeCrAl oxide dispersion-strengthened (ODS) alloy. Through orthogonal experimental design, the influences of laser power (300–320 W), scanning speed (650–850 mm/s), and hatch spacing (0.05–0.07 mm) on the surface morphology and internal defects of as-built samples were analyzed. The microstructural evolution under different volumetric energy densities (VED) was also analyzed. The results indicate that hatch spacing significantly affected crack and pore formation, with minimal defects observed at 0.06 mm. Excessive laser power (320 W) or VED (318.0 J/mm³) led to elevated melt pool temperatures, causing element evaporation, grain coarsening, and preferential oriented texture, thereby reducing hardness to 234 HV. The optimal parameters—laser power of 310 W, scanning speed of 650 mm/s, and hatch spacing of 0.06 mm (VED 265.0 J/mm³)—yielded the highest hardness (293 HV), fine-grained structures, and a high proportion of low-angle grain boundaries (LAGBs) with significant residual stress. This research provides a theoretical foundation for optimizing SLM processes for FeCrAl-ODS alloys.