A review of the wire arc additive manufacturing of metals: properties, defects and quality improvement

By Bintao Wu, Zengxi Pan, Donghong Ding, Dominic Cuiuri, Huijun Li, Jing Xu, John Norrish. Journal of Manufacturing Processes, 2018

1,329 citations recorded by the source corpus.

Abstract Due to the feasibility of economically producing large-scale metal components with relatively high deposition rates, significant progress has been made in the understanding of the Wire Arc Additive Manufacturing (WAAM) process, as well as the microstructure and mechanical properties of the fabricated components. As WAAM has evolved, a wide range of materials have become associated with the process and its applications. This article reviews the emerging research on WAAM techniques and the commonly used metallic feedstock materials, and also provides a comprehensive over view of the metallurgical and material properties of the deposited parts. Common defects produced in WAAM components using different alloys are described, including deformation, porosity, and cracking. Methods for improving the fabrication quality of the additively manufactured components are discussed, taking into account the requirements of the various alloys. This paper concludes that the wide application of WAAM still presents many challenges, and these may need to be addressed in specific ways for different materials in order to achieve an operational system in an acceptable time frame. The integration of materials and manufacturing process to produce defect-free and structurally-sound deposited parts remains a crucial effort into the future.

Subfields: Automotive Engineering, Mechanical Engineering

View Paper: https://www.semanticscholar.org/paper/2df08a45244fa8d9d48d7bb38907ae4400ce036d

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Citations in the corpus

Wire Arc Additive Manufacturing of Stainless Steels: A Review (2020, positive): “A complex deposition path is more likely to produce the spatter ejection or insufficient fusion, Process parameters, such as deposition paths and heat input, cause defects during deposition. creating voids or gaps in the affected areas [33].”
An overview of wire arc additive manufacturing (WAAM) in shipbuilding industry (2020, methodology): “In a study performed with GMAW-based WAAM-fabricated Inconel 718 alloy, Wu et al. (2018) measured the yield and ultimate tensile strength values as 473 ± 6 and 828 ± 8 MPa respectively.”
A review on wire arc additive manufacturing: Monitoring, control and a framework of automated system (2020, methodology): “When compared to laser powder AM methods, WAAM also features better material utilization ratio and more environmental-friendly production process [11].”
Advances in Metal Additive Manufacturing: A Review of Common Processes, Industrial Applications, and Current Challenges (2021, methodology): “Three common welding technologies that might be employed in WAAM systems are Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW) or Plasma Arc Welding (PAW) [35].”
Zero defect manufacturing: state-of-the-art review, shortcomings and future directions in research (2019, background): “The same happens with another review on the same topic WAAM (Wu et al. 2018), they analyse the materials properties and illustrate the common defects produced by WAAM and also how the quality of the produced part can be improved.”
Current Status and Perspectives on Wire and Arc Additive Manufacturing (WAAM) (2019, background): “However, some authors [67] claim that the production of these low-cost alloys by WAAM is only viable for large parts with complex geometries.”