Due to their excellent properties and flexibility, the components made through Wire Arc Additive Manufacturing (WAAM) of aluminium alloys are in huge demand. This review concisely provides the classification of additive manufacturing and WAAM, highlighting the defects during their fabrication, whereas the effect of various parameters involved during WAAM processing are emphasized. The mechanical properties of WAAM-AA are discussed, including as-deposited, horizontal and vertical directions, rolling loads, and heat treatments. Moreover, it addresses the recent advancements of heating and cooling cycles during processing, structural topology optimization and finite element modelling approaches, which can significantly enhance the microstructure and mechanical properties of WAAM-AA. It is recommended to consider process improvement, usage of AI technology and implementation of multi-materials for industrial demands.
Blakey-MilnerBGradlPSneddenG, et al.Metal additive manufacturing in aerospace: a review. Mater Des2021; 209: 110008.
2.
WangZZhangY. A review of aluminum alloy fabricated by different processes of wire arc additive manufacturing. Medziagotyra2021; 27: 18–26.
3.
CookeSAhmadiKWillerthS, et al.Metal additive manufacturing: technology, metallurgy and modelling. J Manuf Process2020; 57: 978–1003.
4.
Kumar SinhaAPramanikSYagatiKP. Research progress in arc based additive manufacturing of aluminium alloys – A review. Meas J Int Meas Confed2022; 200: 111672.
5.
Bhuvanesh KumarMSathiyaP. Methods and materials for additive manufacturing: a critical review on advancements and challenges. Thin-Walled Struct2021; 159: 107228.
6.
OyinloyeTMYoonWB. Stability of 3D printing using a mixture of pea protein and alginate: precision and application of additive layer manufacturing simulation approach for stress distribution. J Food Eng2020; 288: 110127.
7.
HosseiniVACederbergEHurtigK, et al.A physical simulation technique for cleaner and more sustainable research in additive manufacturing. J Clean Prod2021; 285: 124910.
8.
AttaranM. The rise of 3-D printing: the advantages of additive manufacturing over traditional manufacturing. Bus Horiz2017; 60: 677–688.
9.
TshepheTSAkinwamideSOOlevskyE, et al.Additive manufacturing of titanium-based alloys- A review of methods, properties, challenges, and prospects. Heliyon2022; 8: e09041.
10.
PantMPidgePNagdeveL, et al.A review of additive manufacturing in aerospace application. Rev des Compos des Mater Av2021; 31: 109–115.
11.
LeachRKBourellDCarmignatoS, et al.Geometrical metrology for metal additive manufacturing. CIRP Ann2019; 68: 677–700.
12.
PaoliniAKollmannsbergerSRankE. Additive manufacturing in construction: a review on processes, applications, and digital planning methods. Addit Manuf2019; 30: 100894.
13.
BusachiAErkoyuncuJColegroveP, et al.Defining next-generation additive manufacturing applications for the ministry of defence (MoD). Procedia CIRP2016; 55: 302–307.
14.
TyagiVKumarRSinghPL, et al.Barriers in designing and developing products by additive manufacturing for bio-mechanics systems in healthcare sector. Mater Today Proc2021; 50: 1123–1128.
15.
YamazakiT. Development of A hybrid multi-tasking machine tool: integration of additive manufacturing technology with CNC machining. Procedia CIRP2016; 42: 81–86.
16.
NgoTDKashaniAImbalzanoG, et al.Additive manufacturing (3D printing): a review of materials, methods, applications and challenges. Compos Part B Eng2018; 143: 172–196.
17.
AlaghaANHussainSZakiW. Additive manufacturing of shape memory alloys: a review with emphasis on powder bed systems. Mater Des2021; 204: 109654.
18.
LiuJWenP. Metal vaporization and its influence during laser powder bed fusion process. Mater Des2022; 215: 110505.
19.
MostafaeiAElliottAMBarnesJE, et al.Binder jet 3D printing—process parameters, materials, properties, modeling, and challenges. Prog Mater Sci2021; 119: 100707.
20.
BhattPMPeraltaMBruckHA, et al.Robot assisted additive manufacturing of thin multifunctional structures. In: ASME 2018 13th Int Manuf Sci Eng Conf MSEC, 2018, 1: pp.1–10.
21.
AhnDG. Directed Energy Deposition (DED) Process: State of the Art. Korean Society for Precision Engineering. Epub ahead of print2021. DOI: 10.1007/s40684-020-00302-7.
22.
SoundararajanBSofiaDBarlettaD, et al.Review on modeling techniques for powder bed fusion processes based on physical principles. Addit Manuf2021; 47: 102336.
23.
SoniHLimbasiyaNJainA, et al.Investigation of mechanical and surface properties of additively manufactured AlSi10Mg part produced through direct metal laser sintering. Mater Today Proc2022; 62: 7204–7209.
24.
NajmonJCRaeisiSTovarA. Review of additive manufacturing technologies and applications in the aerospace industry. Indianapolis, IN: Elsevier Inc, 2019.
25.
IshfaqKAbdullahMMahmoodMA. A state-of-the-art direct metal laser sintering of Ti6Al4 V and AlSi10Mg alloys: surface roughness, tensile strength, fatigue strength and microstructure. Opt Laser Technol2021; 143: 107366.
26.
ZiaeeMCraneNB. Binder jetting: a review of process, materials, and methods. Addit Manuf2019; 28: 781–801.
27.
OgunsanyaMIsicheiJParupelliSK, et al.In-situ droplet monitoring of inkjet 3D printing process using image analysis and machine learning models. Procedia Manuf2021; 53: 427–434.
28.
LigonSCLiskaRStampflJ, et al.Polymers for 3D printing and customized additive manufacturing. Chem Rev2017; 117: 10212–10290.
29.
WangYYangQLiuX, et al.Microstructure and mechanical properties of amorphous strip/aluminum laminated composites fabricated by ultrasonic additive consolidation. Mater Sci Eng A2019; 749: 74–78.
30.
SvetlizkyDDasMZhengB, et al.Directed energy deposition (DED) additive manufacturing: physical characteristics, defects, challenges and applications. Mater Today2021; 49: 271–295.
31.
TomarBShivaSNathT. A review on wire arc additive manufacturing: processing parameters, defects, quality improvement and recent advances. Mater Today Commun2022; 31: 103739.
32.
SunWShanFZongN, et al.A simulation and experiment study on phase transformations of Ti-6Al-4 V in wire laser additive manufacturing. Mater Des2021; 207: 109843.
33.
LiBWangLWangB, et al.Electron beam freeform fabrication of NiTi shape memory alloys: crystallography, martensitic transformation, and functional response. Mater Sci Eng A2022; 843: 143135.
34.
ShiMXiongJZhangG, et al.Monitoring process stability in GTA additive manufacturing based on vision sensing of arc length. Meas J Int Meas Confed2021; 185: 110001.
35.
FrazierWE. Metal additive manufacturing: a review. J Mater Eng Perform2014; 23: 1917–1928.
36.
KnezovićNTopićA. Wire and arc additive manufacturing (WAAM) - a new advance in manufacturing BT - new technologies, development and application. Mostar: Springer International Publishing AG, 2019.
37.
BakerR.Method of making decorative article, U.S. Patent 1533300. 1925.
38.
EschholzOH. Ornamental Arc Welding, U.S. Patent 1925; 1533239: 7–9.
Rodríguez-GonzálezPRuiz-NavasEMGordoE. Wire arc additive manufacturing (WAAM) for aluminum-lithium alloys: a review. Materials (Basel)2023; 16: 1375.
42.
DickensPMPridhamMSCobbRC, et al. Rapid prototyping using 3-D welding. In: International solid freeform fabrication symposium. 1992, pp.280–290. http://hdl.handle.net/2152/64409.
43.
SpencerJDDickensPMWykesCM. Rapid prototyping of metal parts by three-dimensional welding. Proc Inst Mech Eng Part B J Eng Manuf1998; 212: 175–182.
44.
KorzhykVKhaskinVVoitenkoO, et al.Welding technology in additive manufacturing processes of 3D objects. Mater Sci Forum2017; 906: 121–130.
45.
KovacevicRBeardsleyH. Process control of 3D welding as a droplet-based rapid prototyping technique. In: International solid freeform fabrication symposium. 1998, pp.57–64. https://hdl.handle.net/2152/73429.
46.
DwivediRKovacevicR. Automated torch path planning using polygon subdivision for solid freeform fabrication based on welding. J Manuf Syst2004; 23: 278–291.
47.
JandricZLabudovicMKovacevicR. Effect of heat sink on microstructure of three-dimensional parts built by welding-based deposition. Int J Mach Tools Manuf2004; 44: 785–796.
48.
SongYAParkSChoiD, et al.3D Welding and milling: part I-a direct approach for freeform fabrication of metallic prototypes. Int J Mach Tools Manuf2005; 45: 1057–1062.
49.
SongYAParkSChaeSW. 3D Welding and milling: part II - optimization of the 3D welding process using an experimental design approach. Int J Mach Tools Manuf2005; 45: 1063–1069.
50.
KatouMOhJMiyamotoY, et al.Freeform fabrication of titanium metal and intermetallic alloys by three-dimensional micro welding. Mater Des2007; 28: 2093–2098.
51.
BrandlEBaufeldBLeyensC, et al.Additive manufactured Ti-6A1-4 V using welding wire: comparison of laser and arc beam deposition and evaluation with respect to aerospace material specifications. Phys Procedia2010; 5: 595–606.
52.
DingJColegrovePMehnenJ, et al.Thermo-mechanical analysis of wire and arc additive layer manufacturing process on large multi-layer parts. Comput Mater Sci2011; 50: 3315–3322.
53.
XiongJZhangGGaoH, et al.Modeling of bead section profile and overlapping beads with experimental validation for robotic GMAW-based rapid manufacturing. Robot Comput Integr Manuf2013; 29: 417–423.
54.
ColegrovePACoulesHEFairmanJ, et al.Microstructure and residual stress improvement in wire and arc additively manufactured parts through high-pressure rolling. J Mater Process Technol2013; 213: 1782–1791.
55.
JhavarSJainNKPaulCP. Development of micro-plasma transferred arc (μ-PTA) wire deposition process for additive layer manufacturing applications. J Mater Process Technol2014; 214: 1102–1110.
56.
MontevecchiFVenturiniGScippaA, et al.Finite element modelling of wire-arc-additive-manufacturing process. Procedia CIRP2016; 55: 109–114.
57.
ZhangJWangXPaddeaS, et al.Fatigue crack propagation behaviour in wire + arc additive manufactured Ti-6Al-4V: effects of microstructure and residual stress. Mater Des2016; 90: 551–561.
58.
LiberiniMAstaritaACampatelliG, et al.Selection of optimal process parameters for wire arc additive manufacturing. Procedia CIRP2017; 62: 470–474.
59.
GengHLiJXiongJ, et al.Optimization of wire feed for GTAW based additive manufacturing. J Mater Process Technol2017; 243: 40–47.
60.
LopezABacelarRPiresI, et al.Non-destructive testing application of radiography and ultrasound for wire and arc additive manufacturing. Addit Manuf2018; 21: 298–306.
61.
ZhangXWangKZhouQ, et al.Microstructure and mechanical properties of TOP-TIG-wire and arc additive manufactured super duplex stainless steel (ER2594). Mater Sci Eng A2019; 762: 138097.
62.
LuTLiuCLiZ, et al.Hot-wire arc additive manufacturing Ti–6.5Al–2Zr–1Mo–1 V titanium alloy: pore characterization, microstructural evolution, and mechanical properties. J Alloys Compd2020; 817: 153334.
63.
PriaronePCPagoneEMartinaF, et al.Multi-criteria environmental and economic impact assessment of wire arc additive manufacturing. CIRP Ann2020; 69: 37–40.
64.
KhanAUMadhukarYK. An economic design and development of the wire arc additive manufacturing setup. Procedia CIRP2020; 91: 182–187.
65.
Al-NabulsiZMottramJTGillieM, et al.Mechanical and X ray computed tomography characterisation of a WAAM 3D printed steel plate for structural engineering applications. Constr Build Mater2021; 274: 121700.
66.
DharmendraCRiceKPAmirkhizBS, et al.Atom probe tomography study of κ-phases in additively manufactured nickel aluminum bronze in as-built and heat-treated conditions. Mater Des2021; 202: 109541.
67.
EimerEWilliamsSDingJ, et al.Mechanical performances of the interface between the substrate and deposited material in aluminium wire direct energy deposition. Mater Des2023; 225: 111594.
68.
tingXChenJMiaoJ, et al.Microstructure and mechanical properties of Al–mg–Si/Al–Mg-Sc laminated composite fabricated by wire-arc directed energy deposition. Mater Sci Eng A2024; 894: 146194.
69.
QvalePNjaastadEBBræinT, et al.A fast simulation method for thermal management in wire arc additive manufacturing repair of a thin-walled structure. Int J Adv Manuf Technol2024; 132: 1573–1583.
70.
XuXGangulySDingJ, et al.Enhancing mechanical properties of wire + arc additively manufactured INCONEL 718 superalloy through in-process thermomechanical processing. Mater Des2018; 160: 1042–1051.
71.
CongBDingJWilliamsS. Effect of arc mode in cold metal transfer process on porosity of additively manufactured Al-6.3%Cu alloy. Int J Adv Manuf Technol2015; 76: 1593–1606.
72.
PattanayakSSahooSK. Gas metal arc welding based additive manufacturing—a review. CIRP J Manuf Sci Technol2021; 33: 398–442.
73.
BerminghamMJNicastroLKentD, et al.Optimising the mechanical properties of Ti-6Al-4 V components produced by wire + arc additive manufacturing with post-process heat treatments. J Alloys Compd2018; 753: 247–255.
74.
KarayelEBozkurtY. Additive manufacturing method and different welding applications. J Mater Res Technol2020; 9: 11424–11438.
75.
KleinTSchnallMGomesB, et al.Wire-arc additive manufacturing of a novel high-performance Al-Zn-Mg-Cu alloy: processing, characterization and feasibility demonstration. Addit Manuf2021; 37: 101663.
76.
BusachiAErkoyuncuJColegroveP, et al.Designing a WAAM based manufacturing system for defence applications. Procedia CIRP2015; 37: 48–53.
77.
MüllerJGrabowskiMMüllerC, et al.Design and parameter identification of wire and arc additively manufactured (WAAM) steel bars for use in construction. Metals (Basel)2019; 9: 725. Epub ahead of print 2019. DOI: 10.3390/met9070725.
78.
da SilvaLJScottiFMFernandesDB, et al.Effect of O2 content in argon-based shielding gas on arc wandering in WAAM of aluminum thin walls. CIRP J Manuf Sci Technol2021; 32: 338–345.
79.
ZhuoYYangCFanC, et al.Effect of diameter and content of zirconium dioxide on the microstructure and mechanical properties of the TC17 titanium alloy repaired by wire arc additive manufacture. J Alloys Compd2022; 893: 162295.
80.
XuNShenJHuS, et al.Bimetallic structure of Ti6Al4 V and Al6.21Cu fabricated by cold metal transfer additive manufacturing via Nb interlayer added by TIG. Mater Lett2021; 302: 7–10.
81.
NagasaiBPMalarvizhiSBalasubramanianV. Effect of welding processes on mechanical and metallurgical characteristics of carbon steel cylindrical components made by wire arc additive manufacturing (WAAM) technique. CIRP J Manuf Sci Technol2022; 36: 100–116.
82.
Palmeira BelottiLvan DommelenJAWGeersMGD, et al.Microstructural characterisation of thick-walled wire arc additively manufactured stainless steel. J Mater Process Technol2022; 299: 117373. Epub ahead of print 2022.
83.
ZhangZWangLZhangR, et al.Effect of solution annealing on microstructures and corrosion behavior of wire and arc additive manufactured AZ91 magnesium alloy in sodium chloride solution. J Mater Res Technol2022; 18: 416–427.
84.
YuLChenKZhangY, et al.Microstructures and mechanical properties of NiTi shape memory alloys fabricated by wire arc additive manufacturing. J Alloys Compd2022; 892: 162193.
85.
HorgarAFostervollHNyhusB, et al.Additive manufacturing using WAAM with AA5183 wire. J Mater Process Technol2018; 259: 68–74.
86.
WangJPanZCuiuriD, et al.Phase constituent control and correlated properties of titanium aluminide intermetallic alloys through dual-wire arc additive manufacturing. Mater Lett2019; 242: 111–114.
87.
GokhaleNPKalaPSharmaV.Thin-walled metal deposition with GTAW welding-based additive manufacturing process. J Brazilian Soc Mech Sci Eng2019; 41: 569. Epub ahead of print 2019.
88.
LinJLvYGuoD, et al.Enhanced strength and ductility in thin Ti-6Al-4 V alloy components by alternating the thermal cycle strategy during plasma arc additive manufacturing. Mater Sci Eng A2019; 759: 288–297.
89.
WangKLiuYSunZ, et al.Microstructural evolution and mechanical properties of inconel 718 superalloy thin wall fabricated by pulsed plasma arc additive manufacturing. J Alloys Compd2020; 819: 152936.
90.
WangYChenXKonovalovS, et al.In-situ wire-feed additive manufacturing of Cu-Al alloy by addition of silicon. Appl Surf Sci2019; 487: 1366–1375.
91.
LiuKChenXShenQ, et al.Microstructural evolution and mechanical properties of deep cryogenic treated Cu–Al–Si alloy fabricated by cold metal transfer (CMT) process. Mater Charact2020; 159: 110011.
92.
ZhaoWWeiYZhangX, et al.Comparative investigation of wire arc additive manufacturing of Al-5%Mg alloy with and without external alternating magnetic field. Int J Adv Manuf Technol2022; 119: 2571–2587.
93.
NathRKMajiPSinhaAK, et al.Effect of different electrode angles as well as weld direction on the bead geometry of submerge arc welding process. Mater Today Proc2021; 49: 1793–1798.
94.
LiuDLeeBBabkinA, et al.Research progress of arc additive manufacture technology. Materials (Basel)2021; 14: 1415. Epub ahead of print 2021.
ZengYWangXQinX, et al.Laser ultrasonic inspection of a wire + arc additive manufactured (WAAM) sample with artificial defects. Ultrasonics2021; 110: 106273.
97.
LiuKChenXZhangY, et al.Location dependence of microstructure and mechanical properties of Cu-Al alloy fabricated by dual wire CMT. Mater Res Express2018; 6: 126567.
98.
AamirMGiasinKTolouei-RadM, et al.A review: drilling performance and hole quality of aluminium alloys for aerospace applications. J Mater Res Technol2020; 9: 12484–12500.
99.
HirschJ. Recent development in aluminium for automotive applications. Trans Nonferrous Met Soc China (English Ed2014; 24: 1995–2002.
100.
AzarniyaATaheriAKTaheriKK. Recent advances in ageing of 7xxx series aluminum alloys: a physical metallurgy perspective. J Alloys Compd2019; 781: 945–983.
101.
HosseinabadiOFKhedmatiMR. A review on ultimate strength of aluminium structural elements and systems for marine applications. Ocean Eng2021; 232: 109153.
102.
GuanWGaoGLiJ, et al.Crushing analysis and multi-objective optimization of a cutting aluminium tube absorber for railway vehicles under quasi-static loading. Thin-Walled Struct2018; 123: 395–408.
103.
LuoXRenCWuJ, et al.Experimental and computational insights into self-assembly sodium oleate on anodized aluminum interface in electric field. Corros Sci2022; 203: 110334.
104.
ThreadgilllPLLeonardAJShercliffHR, et al.Friction stir welding of aluminium alloys. Int Mater Rev2009; 54: 49–93.
105.
WangZLinXWangL, et al.Microstructure evolution and mechanical properties of the wire + arc additive manufacturing Al-Cu alloy. Addit Manuf2021; 47: 102298.
106.
XueCZhangYMaoP, et al.Improving mechanical properties of wire arc additively manufactured AA2196 Al–Li alloy by controlling solidification defects. Addit Manuf2021; 43: 102019. Epub ahead of print 2021.
107.
LiangZJinglongLYiL, et al.Characteristics of metal droplet transfer in wire-arc additive manufacturing of aluminum alloy. Int J Adv Manuf Technol2018; 99: 1521–1530.
108.
YehorovYda SilvaLJScottiA. Exploring the use of switchback for mitigating homoepitaxial unidirectional grain growth and porosity in WAAM of aluminium alloys. Int J Adv Manuf Technol2019; 104: 1581–1592.
109.
SunJHenselJKöhlerM, et al.Residual stress in wire and arc additively manufactured aluminum components. J Manuf Process2021; 65: 97–111.
110.
VimalKEKNaveen SrinivasMRajakS. Wire arc additive manufacturing of aluminium alloys: a review. Mater Today Proc2021; 41: 1139–1145.
111.
HeCWeiJLiY, et al.Improvement of microstructure and fatigue performance of wire-arc additive manufactured 4043 aluminum alloy assisted by interlayer friction stir processing. J Mater Sci Technol2023; 133: 183–194.
112.
GuoXLiHPanZ, et al.Microstructure and mechanical properties of ultra-high strength Al-Zn-Mg-Cu-Sc aluminum alloy fabricated by wire + arc additive manufacturing. J Manuf Process2022; 79: 576–586.
113.
KleinTArnoldtALahnsteinerR, et al.Microstructure and mechanical properties of a structurally refined Al–Mg–Si alloy for wire-arc additive manufacturing. Mater Sci Eng A2022; 830: 142318.
114.
HuZXuPPangC, et al.Microstructure and mechanical properties of a high-ductility Al-Zn-Mg-Cu aluminum alloy fabricated by wire and arc additive manufacturing. J Mater Eng Perform2022; 9: 4–9.
115.
ZhouSWuKYangG, et al.Microstructure and mechanical properties of wire arc additively manufactured 205A high strength aluminum alloy: the comparison of as-deposited and T6 heat-treated samples. Mater Charact2022; 189: 111990. Epub ahead of pm.
116.
LangelandsvikGAkselsenOMFuruT, et al.Review of aluminum alloy development for wire arc additive manufacturing. Materials (Basel)2021; 14: 5370.
117.
HuangCWangGSongH, et al.Rapid surface defects detection in wire and arc additive manufacturing based on laser profilometer. Meas J Int Meas Confed2022; 189: 110503.
118.
JafariDVanekerTHJGibsonI. Wire and arc additive manufacturing: opportunities and challenges to control the quality and accuracy of manufactured parts. Mater Des2021; 202: 109471.
119.
LiSZhangLJNingJ, et al.Comparative study on the microstructures and properties of wire + arc additively manufactured 5356 aluminium alloy with argon and nitrogen as the shielding gas. Addit Manuf2020; 34: 101206.
120.
LangelandsvikGHorgarAFuruT, et al.Comparative study of eutectic Al-Si alloys manufactured by WAAM and casting. Int J Adv Manuf Technol2020; 110: 935–947.
121.
QiZCongBQiB, et al.Properties of wire + arc additively manufactured 2024 aluminum alloy with different solution treatment temperature. Mater Lett2018; 230: 275–278.
122.
OropezaDHofmannDCWilliamsK, et al.Welding and additive manufacturing with nanoparticle-enhanced aluminum 7075 wire. J Alloys Compd2020; 834: 154987.
123.
GuJCongBDingJ, et al.WIRE + ARC additive manufacturing of aluminium. In: 25th Annu Int Solid Free Fabr Symp – An Addit Manuf Conf SFF 2014, 2014, pp.451–458.
124.
GuJWangXBaiJ, et al.Deformation microstructures and strengthening mechanisms for the wire + arc additively manufactured Al-Mg4.5Mn alloy with inter-layer rolling. Mater Sci Eng A2018; 712: 292–301.
125.
FangXZhangLChenG, et al.Correlations between microstructure characteristics and mechanical properties in 5183 aluminium alloy fabricated by wire-arc additive manufacturing with different arc modes. Materials (Basel)2018; 11: 2075. Epub ahead of print 2018.
126.
GaoZLiYShiH, et al.Microstructure characteristics under varying solidification parameters in different zones during CMT arc additive manufacturing process of 2319 aluminum alloy. Vacuum2023; 214: 112177.
127.
ZhangLWangSWangH, et al.Mechanical properties and microstructure revolution of vibration assisted wire arc additive manufacturing 2319 aluminum alloy. Mater Sci Eng A2023; 885: 145634.
128.
AldalurESuárezAVeigaF.Metal transfer modes for wire arc additive manufacturing Al-Mg alloys: influence of heat input in microstructure and porosity. J Mater Process Technol2021; 297: 117271. Epub ahead of print 2021.
129.
SuCChenXGaoC, et al.Effect of heat input on microstructure and mechanical properties of Al-Mg alloys fabricated by WAAM. Appl Surf Sci2019; 486: 431–440.
130.
WangJZhuKZhangW, et al.Microstructural and defect evolution during WAAM resulting in mechanical property differences for AA5356 component. J Mater Res Technol2023; 22: 982–996.
131.
ChenCSunGDuW, et al.Effect of equivalent heat input on WAAM Al-Si alloy. Int J Mech Sci2023; 238: 107831.
132.
ZhouLChenFCaoS. Effects of longitudinal alternating magnetic field on the microstructure and properties of CMT-WAAM Al-5 %Mg alloy. Mater Today Commun2024; 41: 110272.
133.
ZhouYLinXKangN, et al.Influence of travel speed on microstructure and mechanical properties of wire + arc additively manufactured 2219 aluminum alloy. J Mater Sci Technol2020; 37: 143–153.
134.
TawfikMMNemat-AllaMMDewidarMM. Effect of travel speed on the properties of Al-Mg aluminum alloy fabricated by wire arc additive manufacturing. J Mater Eng Perform2021; 30: 7762–7769.
135.
YuZYuanTXuM, et al.Microstructure and mechanical properties of Al-Zn-Mg-Cu alloy fabricated by wire + arc additive manufacturing. J Manuf Process2021; 62: 430–439.
136.
WangLSuoYLiangZ, et al.Effect of titanium powder on microstructure and mechanical properties of wire + arc additively manufactured Al-Mg alloy. Mater Lett2019; 241: 231–234.
137.
JinPLiuYLiF, et al.Realization of structural evolution in grain boundary, solute redistribution and improved mechanical properties by adding TiCnpsin wire and arc additive manufacturing 2219 aluminium alloy. J Mater Res Technol2021; 11: 834–848.
138.
LiuKJiangXChenS, et al.Effect of SiC addition on microstructure and properties of Al–Mg alloy fabricated by powder and wire cold metal transfer process. J Mater Res Technol2022; 17: 310–319.
139.
YuanTRenXChenS, et al.Grain refinement and property improvements of Al–Zn–Mg–Cu alloy by heterogeneous particle addition during wire and arc additive manufacturing. J Mater Res Technol2022; 16: 824–839.
140.
ChenFYangYChenC, et al.Effect of La2O3 particle size on the microstructure and properties of Al–Si alloys deposited via wire arc additive manufacturing. J Manuf Process2021; 68: 523–533.
141.
WangYZhangSLiH, et al.Improvement in microstructure and mechanical properties of wire arc additively manufactured 7075 aluminum alloy via adjusting TiC particle addition. Mater Lett2024; 373: 137127. Epub ahead of print 2024.
142.
ZhangCGaoMZengX. Workpiece vibration augmented wire arc additive manufacturing of high strength aluminum alloy. J Mater Process Technol2019; 271: 85–92.
143.
QiZQiBCongB, et al.Microstructure and mechanical properties of wire + arc additively manufactured 2024 aluminum alloy components: as-deposited and post heat-treated. J Manuf Process2019; 40: 27–36.
144.
GuJDingJWilliamsSW, et al.The strengthening effect of inter-layer cold working and post-deposition heat treatment on the additively manufactured Al-6.3Cu alloy. Mater Sci Eng A2016; 651: 18–26.
145.
LiSNingJZhangGF, et al.Microstructural and mechanical properties of wire-arc additively manufactured Al–Zn–Mg aluminum alloy: the comparison of as-deposited and heat-treated samples. Vacuum2021; 184: 109860.
146.
ZhouYLinXKangN, et al.Mechanical properties and precipitation behavior of the heat-treated wire + arc additively manufactured 2219 aluminum alloy. Mater Charact2021; 171: 110735.
147.
GuoYHanQLuW, et al.Microstructure tuning enables synergistic improvements in strength and ductility of wire-arc additive manufactured commercial Al-Zn-Mg-Cu alloys. Virtual Phys Prototyp2022; 17: 649–661.
148.
CongBCaiXQiZ, et al.The effects of ultrasonic frequency pulsed arc on wire + arc additively manufactured high strength aluminum alloys. Addit Manuf2022; 51: 102617.
149.
ZhuKWangJWei-ChenZ, et al.Effect of deposition strategies on microstructures, defects and mechanical properties of 5356 aluminum alloy by wire arc additive manufacturing. Trans Nonferrous Met Soc China (English Ed2024; 34: 423–434.
150.
HönnigeJRColegrovePAGangulyS, et al.Control of residual stress and distortion in aluminium wire + arc additive manufacture with rolling. Addit Manuf2018; 22: 775–783.
151.
AranaMUkarERodriguezI, et al.Influence of deposition strategy and heat treatment on mechanical properties and microstructure of 2319 aluminium WAAM components. Mater Des2022; 221: 110974.
152.
AntunesRAde OliveiraMCL. Effect of surface treatments on the fatigue life of magnesium and its alloys for biomedical applications. Sao Paulo: Elsevier Ltd, 2015.
153.
GuptaKJainNKLaubscherR. Chapter 6: Surface property enhancement of gears. In: Advanced gear manufacturing and finishing.2017, pp.167–196.
154.
SunRLiLZhuY, et al.Microstructure, residual stress and tensile properties control of wire-arc additive manufactured 2319 aluminum alloy with laser shock peening. J Alloys Compd2018; 747: 255–265.
155.
StránskýOPathakSGregorO, et al.Laser shock peening without coating for WAAM printed aluminum alloys: impacts on porosity, microstructure, and surface quality. Opt Laser Technol2025; 192: 113518. Epub ahead of print 2025.
156.
WangCLiYTianW, et al.Influence of ultrasonic impact treatment and working current on microstructure and mechanical properties of 2219 aluminium alloy wire arc additive manufacturing parts. J Mater Res Technol2022; 21: 781–797.
157.
ZhaoWChenFMaW, et al.Effect of ultrasonic power on microstructure and mechanical properties of WAAM 4043 aluminum alloys under ultrasonic-magnetic composite field. J Mater Res Technol2025; 38: 4455–4468.
158.
RenWDingSJiangT, et al.Unraveling the microstructure evolution and strengthening mechanism of WAAM 2319 alloy via pinless friction stir surface processing. Mater Today Commun2024; 49: 113688. Epub ahead of print 2025.
159.
BankongBDAbioyeTEOlugbadeTO, et al.Review of post-processing methods for high-quality wire arc additive manufacturing. Mater Sci Technol (United Kingdom)2023; 39: 129–146.
160.
ZhuRZhangLDuanL, et al.Effects of ultrasonic rotating extrusion assisted wire arc additive manufacturing on the microstructure and mechanical properties of 5356 aluminum alloy. Ultrason Sonochem2025; 114: 107240.
161.
FanYChenFGaoX, et al.Preparation and characterization of high-efficiency deposition WAAM Al–Si alloy assisted through magnetic field regulation and interlayer spraying lanthanum oxide powder. J Manuf Process2024; 124: 1372–1392.
162.
LiGZhangCGaoM, et al.Role of arc mode in laser-metal active gas arc hybrid welding of mild steel. Mater Des2014; 61: 239–250.
163.
SarıkayaMBaşcıl ÖnlerDDağlıS, et al.A review on aluminum alloys produced by wire arc additive manufacturing (WAAM): applications, benefits, challenges and future trends. J Mater Res Technol2024; 33: 5643–5670.
164.
GuJYangSGaoM, et al.Micropore evolution in additively manufactured aluminum alloys under heat treatment and inter-layer rolling. Mater Des2020; 186: 108288.
165.
DerekarKSAddisonAJoshiSS, et al.Effect of pulsed metal inert gas (pulsed-MIG) and cold metal transfer (CMT) techniques on hydrogen dissolution in wire arc additive manufacturing (WAAM) of aluminium. Int J Adv Manuf Technol2020; 107: 311–331.
166.
JorgeVLTeixeiraFRScottiA, et al.The significance of supplementary shielding in WAAM of aluminium thin walls. J Manuf Process2023; 106: 520–536.
167.
GuJDingJWilliamsSW, et al.The effect of inter-layer cold working and post-deposition heat treatment on porosity in additively manufactured aluminum alloys. J Mater Process Technol2016; 230: 26–34.
168.
KaufmannNImranMWischeroppTM, et al.Influence of process parameters on the quality of aluminium alloy en AW 7075 using selective Laser melting (SLM). Phys Procedia2016; 83: 918–926.
169.
GuJBaiJDingJ, et al.Design and cracking susceptibility of additively manufactured Al-Cu-Mg alloys with tandem wires and pulsed arc. J Mater Process Technol2018; 262: 210–220.
170.
OuyangJHWangHKovacevicR. Rapid prototyping of 5356-aluminum alloy based on variable polarity gas tungsten arc welding: process control and microstructure. Mater Manuf Process2002; 17: 103–124.
171.
AntonelloMGBracarenseAQScheuerCJ, et al.Effect of electromagnetic arc constriction applied in GTAW-based wire arc additive manufacturing on walls’ geometry and microstructure. J Manuf Process2021; 71: 156–167.
172.
DebRoyTWeiHLZubackJS, et al.Additive manufacturing of metallic components – process, structure and properties. Prog Mater Sci2018; 92: 112–224.
173.
WuBPanZDingD, et al.A review of the wire arc additive manufacturing of metals: properties, defects and quality improvement. J Manuf Process2018; 35: 127–139.
174.
WangSGuHWangW, et al.The influence of heat input on the microstructure and properties of wire-arc-additivemanufactured Al-Cu-Sn alloy deposits. Metals (Basel)2020; 10: 1–17.
175.
SzostBATerziSMartinaF, et al.A comparative study of additive manufacturing techniques: residual stress and microstructural analysis of CLAD and WAAM printed Ti-6Al-4V components. Mater Des2016; 89: 559–567.
176.
DerekarKSAhmadBZhangX, et al.Effects of process variants on residual stresses in wire arc additive manufacturing of aluminum alloy 5183. J Manuf Sci Eng Trans ASME; 2022; 144: 071005. Epub ahead of print 2022.
177.
da SilvaLJFerraresiHNAraújoDB, et al.Effect of thermal management approaches on geometry and productivity of thin-walled structures of er 5356 built by wire + arc additive manufacturing. Coatings2021; 11: 1141.
178.
MontevecchiFVenturiniGGrossiN, et al.Heat accumulation prevention in wire-arc-additive-manufacturing using air jet impingement. Manuf Lett2018; 17: 14–18.
179.
BaierDWolfFWeckenmannT, et al.Thermal process monitoring and control for a near-net-shape wire and arc additive manufacturing. Prod Eng2022; 16: 811–822.
180.
RodriguesTADuarteVRMirandaRM, et al.Ultracold-Wire and arc additive manufacturing (UC-WAAM). J Mater Process Technol2021; 296: 117196.
181.
SilvaRHGRochaPCJRodriguesMB, et al.Analysis of interlayer idle time as a temperature control technique in additive manufacturing of thick walls by means of cmt and cmt pulse welding processes. Soldag e Insp2020; 25: 1–9.
182.
MinYShenSLiH, et al.Online monitoring of an additive manufacturing environment using a time-of-flight mass spectrometer. Meas J Int Meas Confed2022; 189: 110473.
183.
YuZPanZDingD, et al.A practical fabrication strategy for wire arc additive manufacturing of metallic parts with wire structures. Int J Adv Manuf Technol2021; 115: 3197–3212.
184.
TejaniGGSavsaniVJPatelVK, et al.Size, shape, and topology optimization of planar and space trusses using mutation-based improved metaheuristics. J Comput Des Eng2018; 5: 198–214.
185.
LiuJGaynorATChenS, et al.Current and future trends in topology optimization for additive manufacturing. Struct Multidiscip Optim2018; 57: 2457–2483.
186.
WangYGaoJKangZ. Level set-based topology optimization with overhang constraint: towards support-free additive manufacturing. Comput Methods Appl Mech Eng2018; 339: 591–614.
187.
KandemirVDoganOYamanU. Topology optimization of 2.5D parts using the SIMP method with a variable thickness approach. Procedia Manuf2018; 17: 29–36.
188.
OyamaKDiplasSM’hamdiM, et al.Heat source management in wire-arc additive manufacturing process for Al-Mg and Al-Si alloys. Addit Manuf2019; 26: 180–192.
189.
YulinMXiaomingW. A level set method for structural topology optimization and its applications. Adv Eng Softw2004; 35: 415–441.
190.
RamonellCChacónR.On the topological optimization of horizontal links in eccentrically braced frames. J Constr Steel Res2021; 185: 106887. Epub ahead of print 2021.
191.
SuárezAVeigaFBhujangraoT, et al.Study of the mechanical behavior of topologically optimized arc wire direct energy deposition aerospace fixtures. J Mater Eng Perform2022; 31: 6270–6282.
192.
AbeTSasaharaH. Layer geometry control for the fabrication of lattice structures by wire and arc additive manufacturing. Addit Manuf2019; 28: 639–648.
193.
XiangHHuaLLiZ, et al.High interfacial bonding strength aluminum alloy bimetallic composite plate fabricated by additive manufacturing and rolling hybrid process. J Alloys Compd2025; 1041: 183778.
194.
LiHShiXWuB, et al.Wire arc additive manufacturing: a review on digital twinning and visualization process. J Manuf Process2024; 116: 293–305.
195.
GuoXLiHXueP, et al.Microstructure and mechanical properties of 600MPa grade ultra-high strength aluminum alloy fabricated by wire-arc additive manufacturing. J Mater Sci Technol2023; 149: 56–66.
196.
BagheriMMirsalehiSE. A novel hybrid WAAM-FSP approach for fabrication of ceramic-reinforced aluminum matrix nanocomposites. J Alloys Compd2025; 1042: 183896.
197.
RajendrenVBAbdullahMRAhmadF, et al.Role of graphene in metal matrix functional composites- a review. Compos Interfaces2024; 32: 71.
198.
HauserTReischRTSeebauerS, et al.Multi-Material wire arc additive manufacturing of low and high alloyed aluminium alloys with in-situ material analysis. J Manuf Process2021; 69: 378–390.
