Towards quality controllable strategies in wire-arc directed energy deposition

Abstract Wire-arc directed energy deposition (wire-arc DED) enables the fabrication of large-scale metal components with rapid manufacturing ability and diverse material selection, making it a compelling technology in industries and defenses. However, challenges in both macroscale and microscale defects still limit printed component widespread applications. Recent advances in automatic and intelligent technologies have brought a range of quality controllable strategies to the forefront. This review covers these new strategies for the printing component, including path planning, process monitoring, auxiliary processes, and post processing, while discussing the expectation for structure and quality improvement. In addition, the work brings new areas of intelligent wire-arc DED development, including advances in digital twin, visualization, and human-processing interaction to promote its performance. It is anticipated that a focus on intelligent system will be key to smart and high-quality manufacturing for future wire-arc DED.