23 March 2015 | Donghong Ding, Zengxi Pan, Dominic Cuiuri, Huijun Li
Wire-feed additive manufacturing (AM) is emerging as a promising alternative to traditional subtractive manufacturing for producing large, complex metal components. The current research focuses on achieving high geometric accuracy, surface finish, and material properties to meet the demands of industries such as aerospace, automotive, and rapid tooling. However, wire-feed AM processes often result in high residual stresses and distortions due to excessive heat input and deposition rates. Understanding the impact of process conditions, such as energy input, wire-feed rate, welding speed, deposition pattern, and sequences, on thermal history and residual stresses is crucial. Additionally, the poor accuracy and surface finish limit the widespread application of wire-feed AM. This paper reviews various wire-feed AM technologies and their characteristics, focusing on the quality and accuracy of processed components. The goal is to identify current challenges and suggest future research directions. The introduction highlights the evolution of AM, its advantages over conventional manufacturing methods, and the classification of AM processes for metal components. Wire-feed AM, which uses metal wire instead of powder, offers higher material efficiency and deposition rates but faces trade-offs in resolution and complexity.Wire-feed additive manufacturing (AM) is emerging as a promising alternative to traditional subtractive manufacturing for producing large, complex metal components. The current research focuses on achieving high geometric accuracy, surface finish, and material properties to meet the demands of industries such as aerospace, automotive, and rapid tooling. However, wire-feed AM processes often result in high residual stresses and distortions due to excessive heat input and deposition rates. Understanding the impact of process conditions, such as energy input, wire-feed rate, welding speed, deposition pattern, and sequences, on thermal history and residual stresses is crucial. Additionally, the poor accuracy and surface finish limit the widespread application of wire-feed AM. This paper reviews various wire-feed AM technologies and their characteristics, focusing on the quality and accuracy of processed components. The goal is to identify current challenges and suggest future research directions. The introduction highlights the evolution of AM, its advantages over conventional manufacturing methods, and the classification of AM processes for metal components. Wire-feed AM, which uses metal wire instead of powder, offers higher material efficiency and deposition rates but faces trade-offs in resolution and complexity.