Recent progress in wire arc additive manufacturing of magnesium alloys

• The effect of process parameters on microstructure and mechanical properties are systematically summarized. • Strengthening mechanism and unique corrosion behavior of WAAM-Mg alloys are discussed. • Optimization strategies are proposed to balance strength and ductility of WAAM-Mg alloys. • Current challenges of WAAM-Mg alloys are revealed, and future research directions are proposed. Wire arc additive manufacturing (WAAM) has emerged as a promising technique for processing magnesium (Mg) alloys, offering advantages such as near-net-shape forming, high deposition efficiency, and the ability to fabricate complex geometries. The growing demand for lightweight materials in aerospace and defense applications has further fueled the integration of WAAM with Mg alloys, known for their exceptional specific strength. This combination not only enhances design flexibility but also overcomes the limitations of traditional manufacturing methods, accelerating industrial adoption. This review consolidates the current understanding of WAAM-fabricated Mg alloys, focusing on key aspects such as arc heat source classifications, the relationship between process parameters and deposition characteristics, and microstructural strategies to achieve an optimal strength-ductility balance. We also explore the underlying mechanisms influencing mechanical performance and corrosion resistance. Finally, the review summarizes existing challenges and proposes promising research directions to promote the application of WAAM-processed Mg alloys in various industries.