Work

Wire Arc Additive Manufacturing (WAAM): A comprehensive review of process, materials, modelling, artificial intelligence, and industrial applications

Year: 2026

Type: article

Abstract: This paper presents a comprehensive review of Wire Arc Additive Manufacturing (WAAM), a metal additive manufacturing technique that produces near-net-shape components through layer-by-layer deposition of metal wire using an electric arc as the heat source. WAAM bridges conventional arc welding and additive manufacturing, offering high deposition rates, superior material utilization, scalability, and cost-effectiveness for large metallic structures. The review covers the fundamentals of WAAM, including process principles, system components, and key variants. It critically analyzes how major process parameters, current, voltage, wire feed rate, and travel speed, influence bead geometry, heat input, microstructure, and mechanical performance. Commonly employed materials such as titanium, Aluminium, steel, and nickel-based superalloys are examined with respect to processability, microstructural evolution, and resulting properties. Advances in control, monitoring, and modelling are highlighted, focusing on closed-loop feedback systems, digital twins, and machine-learning-based optimization for enhanced stability and reproducibility. Persistent challenges remain in dimensional accuracy, surface roughness, porosity, residual stress, and certification of AM-grade feedstock. Future directions emphasize hybrid FEM–AI/ML modelling, real-time adaptive control, energy-efficient design, and sustainable material utilization via wire recycling to enable the full industrial adoption of WAAM across aerospace, automotive, and marine sectors.

Source: Journal of Alloys and Compounds

DOI: 10.1016/j.jallcom.2026.186347