Research progress on arc-based additive repair (AAR) technology for metal parts

Abstract Arc-based additive additive technology, like other additive manufacturing technologies such as laser cladding, cold spraying, has been used in repairing metal parts that suffer harsh working conditions, including wear, corrosion, and breaking which prevent them from realising an economic development route when lifespan is extended. However, there is a limitation in the existing study of arc-based additive repair technology. against the backdrop of the rapid development of many emerging technologies, such as artificial intelligence. Hence, this paper aims to provide a holistic status quo of arc-based additive repairing technology (AAR) which includes five sections: Firstly, AAR is overviewed and then followed by types of AAR that provide an understanding of explicit AAR technique, such as powder plasma arc welding, plasma-transfer arc welding, gas metal arc welding, and gas tungsten arc welding. Secondly, parameters optimization characteristics and performance improvement measures related to arc energy density, shielding gas flow rate, tool path, and additional energy field are presented. Thirdly, defects and enhancing methods, including inner gas porosity, distortion and deformation, and cracks and corresponding addressing approaches, are discussed. Finally, challenges like efficiency and complexity of processes, defect control and quality assurance, and process displacement and geometric accuracy are concluded, and trends of AAR are proposed. Through this review, a new picture of the current state of AAR research unfolds that expect to inspire a sight-clear future.