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<p>Arc-based additive manufacturing (Arc-AM) has emerged as a cutting-edge technology owing to its high deposition rate, large build envelope, and lower capital cost compared to other heat sources, like laser-based systems. The wire feeding and arc source-AM technologies, namely, wire arc additive manufacturing (WAAM), are employed with gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), plasma transferred arc welding (PTAW), and hybrid layer manufacturing (HLM) processes for enhancing deposited material properties. This review article elucidates on the current state and prospects of novel materials used to fabricate components using the WAAM process. The investigation has discussed process characteristics, parameter optimization, deposition quality, and microstructure evolution in various metal alloys, whereas the challenges related to bead geometry, deposition energy control, and residual stress are delineated, along with sustainable solutions including robotic automation, in-situ monitoring, and additive-subtractive integration during the additive manufacturing of components. Therefore, the present article demonstrates quick and facile regarding WAAM that implies strong potential for the cost-effective fabrication of large, fully dense metallic parts that are applicable across aerospace, marine, and tooling industries.</p>

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Review: state-of-art for wire arc additive manufacturing of metallic alloys—insights into materials, methods, and future prospects

  • 期刊论文

  • 发表日期：

    2026年7月2日

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  • Suresh Goka,
  • M. Manjaiah,
  • M. J. Davidson,
  • Syed Quadir Moinuddin

摘要

Arc-based additive manufacturing (Arc-AM) has emerged as a cutting-edge technology owing to its high deposition rate, large build envelope, and lower capital cost compared to other heat sources, like laser-based systems. The wire feeding and arc source-AM technologies, namely, wire arc additive manufacturing (WAAM), are employed with gas metal arc welding (GMAW), gas tungsten arc welding (GTAW), plasma transferred arc welding (PTAW), and hybrid layer manufacturing (HLM) processes for enhancing deposited material properties. This review article elucidates on the current state and prospects of novel materials used to fabricate components using the WAAM process. The investigation has discussed process characteristics, parameter optimization, deposition quality, and microstructure evolution in various metal alloys, whereas the challenges related to bead geometry, deposition energy control, and residual stress are delineated, along with sustainable solutions including robotic automation, in-situ monitoring, and additive-subtractive integration during the additive manufacturing of components. Therefore, the present article demonstrates quick and facile regarding WAAM that implies strong potential for the cost-effective fabrication of large, fully dense metallic parts that are applicable across aerospace, marine, and tooling industries.