International Journal of Extreme Manufacturing, Volume. 7, Issue 4, 42004(2025)

Towards quality controllable strategies in wire-arc directed energy deposition

Gao Hanqi, Li Hengrui, Shao Dandan, Fang Naiwen, Miao Yugang, Pan Zengxi, Li Huijun, Zhang Bo, Peng Zhike, and Wu Bintao

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.

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Gao Hanqi, Li Hengrui, Shao Dandan, Fang Naiwen, Miao Yugang, Pan Zengxi, Li Huijun, Zhang Bo, Peng Zhike, Wu Bintao. Towards quality controllable strategies in wire-arc directed energy deposition[J]. International Journal of Extreme Manufacturing, 2025, 7(4): 42004

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Paper Information

Category: Topical Review

Received: Sep. 16, 2024

Accepted: Sep. 9, 2025

Published Online: Sep. 9, 2025

The Author Email:

DOI:10.1088/2631-7990/adb9a9

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