Multi-material components featuring high performance and design flexibility have attracted considerable attention, providing solutions to meet the performance demands of high-end equipment components. Achieving material diversity in additive manufacturing (AM) is a fundamental step towards manufacturing multi-material components. Wire arc additive manufacturing (WAAM), an important branch of AM technology, boasts notable advantages in the efficient and customized preparation of large-scale parts due to its high deposition efficiency and unrestricted forming size. However, achieving material diversity in WAAM, constrained by its reliance on wire-form raw materials, has emerged as a compelling challenge. Wire innovation, including multiple, stranded, and cored wires, have furnished solutions to this challenge. To this end, this review provides an overview of the current developments in WAAM via wire innovation and suggests future research directions, aiming to serve as a reference for the further advancement of WAAM. Initially, the article introduces several WAAM printing forms, their manufacturing features, printable materials and inherent manufacturing limitations, and the intermixing of metal constituents of WAAM, prior to highlighting the advantages and necessity of achieving material diversity. Subsequently, the exposition of multi-wire-arc AM demonstrates its utility in the preparation of binary or ternary alloys, inclusive of intermetallic compounds and functionally graded materials, responding adeptly to the deficiencies of conventional WAAM, which is limited to single-material printing. The merits and progression of stranded-wire-arc AM for high-entropy alloy production are synthesized and debated, especially given that creating components with multiple metal elements via multi-wire-arc AM customarily confronts the constraint of necessitating more intricate manufacturing equipment and processes. Further, the review explores the recently developed cored-wire-arc AM technology, which actualizes the manufacturing of composite materials, amalgamating metals and non-metals, to remedy the issues encountered with standard WAAM, incapable of realizing non-metallic material printing. Considering machine tools as an important means to achieve material diversity in WAAM, we expand on the current machine tool architecture and its corresponding design tools. Finally, the current research status on WAAM via wire innovation is summarized and potential future research directions are proposed. 

Achieving material diversity in wire arc additive manufacturing: Leaping from alloys to composites via wire innovation

Metal transfer behavior during CMT-based Wire Arc Additive Manufacturing of Ti-6Al-4V alloy

Mechanism and technology evaluation of a novel alternating-arc-based directed energy deposition method through polarity-switching self-adaptive shunt

Optimizing forming accuracy and improving deposition rate are the research hotspots in directed energy deposition (DED) of the aluminum alloy structures with medium-to-large size. This work employed a self-designed external compound magnetic fields (ECMFs) to enhance DED efficiency and forming accuracy simultaneously. Compared with the results of gas metal arc welding-based conventional-deposition-rate DED process with a low wire feeding rate, the deposition rate of the ECMFs assisted DED process was increased by 93.42%, surface roughness for each side of the cross-sectional samples was decreased by 52.86% and 82.73%, and the average grain size in the top and middle regions was decreased by 5.18% and 52.48%, respectively. The reasons for the high forming accuracy and acceptable mechanical property were explained distinctly. This novel method realized the high deposition rate of the DED process with good formability and performance. 

Investigation on High-deposition-rate Directed Energy Deposition of Al-5%Mg Alloy Via External Compound Magnetic Fields

To address the issues of low deposition efficiency, poor geometric accuracy, and high porosity in wire arc additive manufacturing (WAAM) specimens, a longitudinal alternating current (AC) magnetic field-assisted WAAM method was employed. The results showed that the introduction of the longitudinal AC magnetic field significantly enhanced the geometric accuracy of the specimens. After magnetic field assistance, the porosity of the WAAM Al-5%Mg alloy specimens decreased from 0.372 % to 0.016 %. The grain size decreases from 71.95 μm to 56.3 μm, with a notable increase in the proportion of small grains (D < 30 μm) from 27.06 % to 44.57 %. The longitudinal tensile strength increased from 243 MPa to 260 MPa, while the transverse tensile strength increased from 232 MPa to 257.7 MPa. Moreover, the longitudinal and transverse tensile strengths tended to be isotropic. Therefore, the longitudinal AC magnetic field has a significant impact on the performance of AlMg alloy WAAM specimens. This study presents novel strategies and theoretical guidance for enhancing the efficiency and component performance of aluminum alloy WAAM technology. 

Enhancing the geometry accuracy and mechanical properties of wire arc additive manufacturing of an Al-5%Mg alloy through longitudinal magnetic field influence

Study on the droplet transfer behavior and microstructure of wire arc additive manufactured Inconel 718 alloy assisted by an alternating magnetic field

Comparative Study on the Microstructure, Mechanical Properties and Fracture Mechanism of Wire Arc Additive Manufactured Inconel 718 Alloy Fabricated by Cold Metal Transfer Process Under the Assistance of Alternating Magnetic Field

In this paper, the droplet transfer behavior, geometric characteristics of weld bead and formability of CMT MIX + Synchropulse (CSP) wire + arc additively manufactured Inconel 718 alloy under high wire feeding speed are studied. The results show that a CSP cycle is composed of a CSP high-frequency pulse stage (CSP–HFP) and CSP-CMT stage, and the periods ratio is about 1.7:1. The high frequency and large average welding current of CSP-HFP increase the arc force, which further increases the droplet impact force on the molten pool. The molten pool is significantly deformed, resulting in the penetration depth of the CSP weld bead (1.8 mm) apparently higher than that of CMT (0.5 mm). The surface of the CMT-WAAM sample is more rough and irregular. The large penetration depth provides sufficient support for the molten pool, which promotes the overall stability of the molten pool. The increase of the droplet impact and arc forces enhance the convections in the molten pool, which finally suppresses the overflow phenomenon. 

Study on droplet transition behavior, bead geometric characteristics and formability of wire + arc additively manufactured Inconel 718 alloy by using CMT MIX+ Synchropulse process

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Study on the droplet transfer behavior and microstructure of wire arc additive manufactured Inconel 718 alloy assisted by an alternating magnetic field

Comparative Study on the Microstructure, Mechanical Properties and Fracture Mechanism of Wire Arc Additive Manufactured Inconel 718 Alloy Fabricated by Cold Metal Transfer Process Under the Assistance of Alternating Magnetic Field

Study on droplet transition behavior, bead geometric characteristics and formability of wire + arc additively manufactured Inconel 718 alloy by using CMT MIX+ Synchropulse process