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<p>The decade from 2015 to 2025 marks a transformative period in the evolution of wire arc additive manufacturing (WAAM), a technology that has steadily advanced from experimental setups to industry-scale applications. This review narrates WAAM journey as it evolved into a reliable solution for fabricating large, complex metal components with high deposition rates and cost efficiency over this period. The growing volume of research publications (analysed chronologically and geographically for each technique of WAAM) over this period highlights global interests, particularly in refining WAAM techniques to either mitigate or control the issues such as porosity, residual stresses, heat accumulation, and dimensional accuracy. Therefore, a detailed review of innovative strategies introduced by researchers from time to time addressing these challenges is also included. Moreover, the versatility of the WAAM application in processing high work-function materials and low work-function materials is also reviewed and discussed, which enables its adoption in aerospace, defence, marine, and energy sectors. Also, a review of present and future directions related to further enhance the applicability of WAAM with the aim of quality improvement in metals and alloys is also concluded. This review captures the technological, material, and strategic advancements over the decade of 2015–2025 that have propelled WAAM forward, setting the stage for its integration into next-generation manufacturing environments guided by Industry 4.0 principles.</p>

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WAAM 2015–2025: A review of technological advancements, material applications, and emerging directions

  • 期刊论文

  • 发表日期：

    2025年11月4日

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  • Parveen Kumar,
  • Satish Kumar Sharma,
  • Ratnesh Kumar Raj Singh,
  • Mandeep Kumar,
  • Manish Singh

摘要

The decade from 2015 to 2025 marks a transformative period in the evolution of wire arc additive manufacturing (WAAM), a technology that has steadily advanced from experimental setups to industry-scale applications. This review narrates WAAM journey as it evolved into a reliable solution for fabricating large, complex metal components with high deposition rates and cost efficiency over this period. The growing volume of research publications (analysed chronologically and geographically for each technique of WAAM) over this period highlights global interests, particularly in refining WAAM techniques to either mitigate or control the issues such as porosity, residual stresses, heat accumulation, and dimensional accuracy. Therefore, a detailed review of innovative strategies introduced by researchers from time to time addressing these challenges is also included. Moreover, the versatility of the WAAM application in processing high work-function materials and low work-function materials is also reviewed and discussed, which enables its adoption in aerospace, defence, marine, and energy sectors. Also, a review of present and future directions related to further enhance the applicability of WAAM with the aim of quality improvement in metals and alloys is also concluded. This review captures the technological, material, and strategic advancements over the decade of 2015–2025 that have propelled WAAM forward, setting the stage for its integration into next-generation manufacturing environments guided by Industry 4.0 principles.