This study explores an innovative method to enhance Directed Energy Deposition (DED) of aluminum 5356 products by integrating an electromagnetic vibration system into the DED setup. The application of vibrations significantly improved surface quality, reducing surface waviness and increasing building efficiency by 14%, from 78.5% to 92.25%.Gas porosity was reduced from 1.5 ± 0.04% in as-built (AB) components to 0.34 ± 0.07% in vibration-assisted (VA) parts. Tensile tests showed a marked reduction in anisotropy, with the tensile strength deviation between the x and z directions decreasing to less than 0.4% for vibration-assisted samples, compared to 7.9% for asbuilt ones. Additionally, secondary phase analysis revealed a homogenization effect, with magnesium- and iron-rich precipitates displaying a finer dispersion (3.57 ± 3.42 µm²) compared to 11.28 ± 12.49 µm² in as-built parts. Overall, the findings highlight the potential of vibration-assisted DED to improve part properties, reduce defects, and advance the DED manufacturing process.
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