Heat sources in wire arc additive manufacturing and their impact on macro-microstructural characteristics and mechanical properties – An overview

Abstract

The layer-by-layer production idea known as Wire Arc Additive Manufacturing (WAAM) is suggested as a viable substitute for conventional subtractive methods because of its ability to produce massive metallic components with a moderate degree of geometric complexity. This technology has garnered attention recently because of its advantages over traditional Additive Manufacturing (AM) procedures, namely its low cost and high deposition rates. This review investigated various electric arc heat inputs and energy sources for the material depositing processes of gas tungsten arc welding (GTAW), gas metal arc welding (GMAW), cold metal transfer (CMT), plasma arc welding (PAW)-based wire arc additive manufacturing systems. This is achieved through the application of a thorough methodology for comprehending the primary process factors and their impact on the final component qualities. In the present review, the macro-microstructure and mechanical behavior were examined with respect to various energy sources and electric arc heat inputs. This review also examines the input elements related to heat on the wire arc additive manufacturing process. It is necessary to describe the factors influencing these features in order to determine the best wire arc additive manufacturing technique in terms of heat input. The principal aim of the review is to investigate the correlation between heat input and the mechanical, microstructural, and macrostructural features of parts deposited using wire arc additive manufacturing technology. The heat input, which is thoroughly examined in this study, is crucial to the stability of the wire arc additive manufacturing process and affects the mechanical characteristics and microstructural development of the parts during the manufacturing process. The review addresses a wide range of materials, including aluminium alloys, copper alloys, steel alloys, nickel alloys, iron alloys, titanium alloys, magnesium alloys, and smart materials, with a focus on their microstructure, macrostructure, and mechanical properties, providing significant insights into their application across many industries.