A state of the art review of wire arc additive manufacturing (WAAM) - part2: process improvements and industrial applications

Wire Arc Additive Manufacturing (WAAM) has emerged as a transformative technology for producing large-scale metal components, offering significant advantages in material efficiency and manufacturing flexibility. This comprehensive review examines recent advances in WAAM technology, systematically analyzing developments across process improvements, monitoring approaches, and industrial applications. The analysis begins with an evaluation of parameter optimization strategies, examining the relationships between process variables and component quality through statistical and machine learning approaches. Attention is given to innovative in-situ process modifications, including friction stir processing, interpass rolling, and dynamic cooling strategies, assessing their effectiveness in enhancing material properties and reducing residual stresses. The review extensively discusses the integration of advanced monitoring systems, including thermal imaging, geometric scanning, and multi-sensor frameworks, alongside simulation approaches that enable improved process control and quality assurance. A detailed examination of post-processing techniques evaluates their role in achieving desired component properties and industry-specific requirements. The paper provides an in-depth analysis of WAAM’s implementation across various industries, including aerospace, automotive, marine, construction, and energy sectors, presenting specific case studies that demonstrate both capabilities and challenges. Through systematic evaluation of current limitations in process control, material properties, and quality assurance, the review identifies critical research gaps and promising future directions. This comprehensive examination offers valuable insights for researchers and practitioners working to advance WAAM technology, providing a foundation for future developments in large-scale metal additive manufacturing.