A state of the art review of wire arc additive manufacturing (WAAM)–part 1: process fundamentals, parameters and materials

This comprehensive review examines wire arc additive manufacturing (WAAM) with a focus on process fundamentals, operational parameters, material characteristics, and quality aspects. Through systematic comparison with other metal additive manufacturing (AM) techniques, we elucidate the distinct advantages and limitations of WAAM, highlighting specific niches where this technology excels. The review provides an in-depth analysis of WAAM process parameters, including current, voltage, travel speed, wire feed rate, and their effects on deposit characteristics. A detailed examination of materials predominantly used in WAAM offers insights into process compatibility and material-specific challenges. The paper extensively investigates prevalent defects, their relationship with process parameters, and their influence on part quality. Finally, we analyze the microstructural and mechanical characterization of WAAM components across different materials and processing conditions. This review aims to provide researchers and practitioners with a fundamental understanding of WAAM technology, its capabilities, and current limitations.