Comprehensive analysis of experimental studies in cold metal transfer welding

Cold metal transfer (CMT) welding has emerged as a transformative technology in metal joining, offering minimal heat input, reduced distortion, and superior deposition control. This review synthesizes experimental studies to evaluate CMT's capabilities in aerospace, automotive, and additive manufacturing applications. Key findings demonstrate that optimized parameters achieve dimensional accuracies within ± 0.2 mm, heat-affected zones 40–60% narrower than conventional GMAW, and grain refinement (12–18 μm) enhancing mechanical properties. Hybrid CMT-laser methods improve deposition rates by 15–30%, while numerical models predict thermal behavior with > 90% accuracy. However, challenges persist in residual stress management for thick sections and standardized protocols for dissimilar materials. Future research must prioritize real-time monitoring, machine-learning-assisted optimization, and comprehensive testing standards to expand CMT's industrial adoption.