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<p>Wire arc additive manufacturing (WAAM) has emerged as a transformative fabrication and repair technology for large-scale metallic components in marine environments, offering high deposition rates and near-net-shape material efficiency applicable to icebreakers, naval vessels, and luxury ships. This review synthesizes findings from studies published between 2015 and 2025 on the material–process–property relationships governing WAAM-fabricated Ni–Al Br, high-strength low-alloy steels, and stainless steels for marine applications. A unified thermal-history framework is introduced to explain the mechanistic pathway linking process parameters, solidification and reheating, microstructural gradients, and direction-dependent mechanical properties across alloy systems. This review critically evaluates residual-stress evolution and mitigation, mechanical anisotropy, corrosion mechanisms encompassing passive-film stability and pitting initiation, cavitation-erosion resistance, and build-height-dependent microstructural heterogeneity. A statistical assessment of inter-study scatter in hardness and tensile data identifies key sources of variability and their implications for design allowable. WAAM is compared with competing processes, laser powder bed fusion, laser directed energy deposition, and cold spray, and critical certification gaps within Det Norske Veritas and American Bureau of Shipping frameworks are identified. Priority research directions for certified marine deployment are outlined.</p>

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Wire-arc additive manufacturing for metallic components in marine environment: a critical review of material–process–property relationships

  • 期刊论文

  • 发表日期：

    2026年7月27日

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  • Mojtaba Karamimoghadam,
  • Ahmad Mobasher Amini,
  • Payam Shafie,
  • Charles Lagacé-Leblanc,
  • Giuseppe Casalino,
  • Mousa Javidani

摘要

Wire arc additive manufacturing (WAAM) has emerged as a transformative fabrication and repair technology for large-scale metallic components in marine environments, offering high deposition rates and near-net-shape material efficiency applicable to icebreakers, naval vessels, and luxury ships. This review synthesizes findings from studies published between 2015 and 2025 on the material–process–property relationships governing WAAM-fabricated Ni–Al Br, high-strength low-alloy steels, and stainless steels for marine applications. A unified thermal-history framework is introduced to explain the mechanistic pathway linking process parameters, solidification and reheating, microstructural gradients, and direction-dependent mechanical properties across alloy systems. This review critically evaluates residual-stress evolution and mitigation, mechanical anisotropy, corrosion mechanisms encompassing passive-film stability and pitting initiation, cavitation-erosion resistance, and build-height-dependent microstructural heterogeneity. A statistical assessment of inter-study scatter in hardness and tensile data identifies key sources of variability and their implications for design allowable. WAAM is compared with competing processes, laser powder bed fusion, laser directed energy deposition, and cold spray, and critical certification gaps within Det Norske Veritas and American Bureau of Shipping frameworks are identified. Priority research directions for certified marine deployment are outlined.