Abstract: 【Objective】 This study aims to address the prevalent cracking issue in selective laser melting（SLM） of superalloys by designing a novel Ni-Fe-Cr-Al alloy tailored for SLM processing. The research focuses on investigating the effects of key SLM parameters on the formability, microstructure, and mechanical properties of the alloy, with the goal of establishing a suitable processing window and providing insights into the composition design of crack-resistant alloys for additive manufacturing.【Method】 A Ni-Fe-Cr-Al alloy powder with a nominal composition of 41.0% Ni, 39.0% Fe, 16.5% Cr, and 3.5% Al（by weight） was prepared via gas atomization. SLM trials were conducted using a commercial SLM system under an argon atmosphere with oxygen content below 0.03%. The layer thickness was fixed at 50 μm with an interlayer rotation of 67°. A systematic parameter matrix covering laser powers from 110 to 230 W and scanning speeds from 300 to 1 100 mm/s was employed, corresponding to volumetric energy densities ranging from 29.9 to 69.8 J/cm³. The relative density of as-built samples was measured by the Archimedes method. Microstructural characterization was performed using optical microscopy, X-ray diffraction, scanning electron microscopy, and electron backscatter diffraction. Mechanical properties were evaluated via Vickers microhardness testing and uniaxial tensile testing at room temperature.【Result】 The results indicate that fully dense Ni-Fe-Cr-Al samples（relative density >99.3%） can be achieved when the laser power exceeds 140 W and the energy density is between 43.81 and 53.97 J/cm³. The optimal combination of laser power（200 W） and scanning speed（800 mm/s） yielded the highest density of 99.88%. Microstructural analysis revealed that the alloy consists primarily of a single γ-（Fe, Ni） austenitic phase. The as-built microstructure exhibits a mixture of columnar and equiaxed grains with an average grain size of 30.38 μm and a pronounced 〈100〉 texture along the build direction. Submicron cellular substructures（～1 μm） were observed within the grains. The optimized sample showed an average microhardness of 212 HV0.1, a yield strength of 545.86 MPa, a tensile strength of 696.33 MPa, and an elongation of 27.8%. Fracture surfaces displayed typical ductile dimple features, although some micro-porosity was present.【Conclusion】 The newly designed Ni-Fe-Cr-Al alloy demonstrates excellent SLM processability with a wide window of defect-free parameters. The combination of moderate alloying, a narrow solidification range, and optimized SLM parameters effectively suppresses cracking and achieves high density. The fine cellular substructure and grain refinement induced by rapid solidification contribute significantly to the enhanced strength while maintaining good ductility. This work provides a viable compositional and processing strategy for developing crack-resistant, medium-temperature alloys for laser additive manufacturing, offering valuable guidance for future alloy design targeting SLM applications.