In-situ manufacturing of ODS FeCrAlY alloy via laser powder bed fusion

•Ball milling is eliminated by the internal oxidation mechanism.•Y–Al–O-enriched oxide nanoparticles had diameters of 10–100 nm.•High enthalpy for oxide formation, and high density of defects activated internal oxidation. Gas-atomized Fe–24Cr–8Al–0.5Y (wt.%) powder was used as a feedstock in a laser powder bed fusion process with nitrogen atmosphere. Formation of Al–Y–O-enriched nanoparticles with diameters of 10–100 nm implied in-situ precipitation of Al–Y–O-enriched nanoparticles within the ferritic matrix developing an oxide dispersion strengthened FeCrAl alloy without any mechanical alloying. Thermodynamics and kinetics of the internal oxidation during rapid solidification of laser powder bed fusion process are discussed.