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<p>Wire arc additive manufacturing (WAAM) has gained considerable attention as an efficient technique for producing large-scale metallic components, offering benefits such as high deposition rate, cost-effectiveness, and geometric flexibility. However, its broader industrial adoption remains limited due to challenges including poor surface finish, porosity, residual stress accumulation, dimensional distortion, and anisotropic mechanical properties. To overcome these limitations, hybrid WAAM approaches that incorporate additional thermal, mechanical, or subtractive treatments have been developed to improve component quality and structural integrity. This review begins with a focused assessment of key process variables including travel speed, wire feed rate, heat input, and shielding gas flow rate. These parameters are consistently reported to significantly affect bead morphology, microstructural characteristic, and mechanical performance in WAAM-processed Ti–6Al–4V components. The thermal history induced by successive layer deposition promotes the development of columnar <i>β</i> phase grains and micro-segregation, which strongly influence microstructure evolution and deformation behavior. The resulting <i>α</i> and <i>β</i> phase lamellar structures, along with non-uniform dispersal of alloying elements, introduce local variations in strength and ductility. Concurrently, efforts to establish process–structure–property–performance relationships through experimental and simulation-based studies have offered valuable insight into the underlying mechanisms. Machine learning (ML) methods are increasingly being applied to capture the complex and nonlinear relationships among process parameters, material response, and final part performance, enabling more adaptive and predictive control strategies. This review outlines the current state of the art in hybrid WAAM of Ti–6Al–4V, identifies key scientific and technological gaps, and outlines future research directions to advance the adoption of WAAM for high-performance structural applications.</p>

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Hybrid wire arc additive manufacturing techniques for Ti–6Al–4V functional components

  • 期刊论文

  • 发表日期：

    2025年11月1日

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  • Dhruv Kumar,
  • Vipin,
  • Reeta Wattal

摘要

Wire arc additive manufacturing (WAAM) has gained considerable attention as an efficient technique for producing large-scale metallic components, offering benefits such as high deposition rate, cost-effectiveness, and geometric flexibility. However, its broader industrial adoption remains limited due to challenges including poor surface finish, porosity, residual stress accumulation, dimensional distortion, and anisotropic mechanical properties. To overcome these limitations, hybrid WAAM approaches that incorporate additional thermal, mechanical, or subtractive treatments have been developed to improve component quality and structural integrity. This review begins with a focused assessment of key process variables including travel speed, wire feed rate, heat input, and shielding gas flow rate. These parameters are consistently reported to significantly affect bead morphology, microstructural characteristic, and mechanical performance in WAAM-processed Ti–6Al–4V components. The thermal history induced by successive layer deposition promotes the development of columnar β phase grains and micro-segregation, which strongly influence microstructure evolution and deformation behavior. The resulting α and β phase lamellar structures, along with non-uniform dispersal of alloying elements, introduce local variations in strength and ductility. Concurrently, efforts to establish process–structure–property–performance relationships through experimental and simulation-based studies have offered valuable insight into the underlying mechanisms. Machine learning (ML) methods are increasingly being applied to capture the complex and nonlinear relationships among process parameters, material response, and final part performance, enabling more adaptive and predictive control strategies. This review outlines the current state of the art in hybrid WAAM of Ti–6Al–4V, identifies key scientific and technological gaps, and outlines future research directions to advance the adoption of WAAM for high-performance structural applications.