Challenges and developments in wire arc additive manufacturing of steel: a review.

Dekis, Mohamed; Tawfik, Mahmoud; Egiza, Mohamed; Dewidar, Montaser

Abstract

Wire Arc Additive Manufacturing (WAAM) offers significant potential for enhancing steel component production. This study addresses critical challenges, including defect formation, process optimization, and property enhancement. By categorizing defects such as porosity, cracks, and lack of fusion, and correlating them with process parameters like wire feed rate and travel speed, we identify key factors influencing component quality. Our findings reveal that porosity can reduce tensile strength by 15-20% and fatigue life by up to 50%, while cracks can lead to a strength reduction of up to 30%. To mitigate these issues, we explore process optimization, post-processing techniques, and emerging technologies. By implementing strategies to control heat input, reduce residual stresses, and refine microstructure, we aim to improve build quality, mechanical properties, and overall component performance. This research provides valuable insights for industry practitioners to advance steel WAAM applications and overcome existing challenges.

Citation

DEKIS, M., TAWFIK, M., EGIZA, M. and DEWIDAR, M. [2025]. Challenges and developments in wire arc additive manufacturing of steel: a review. Results in engineering [online], In Press, article number 104657. Available from: https://doi.org/10.1016/j.rineng.2025.104657

• Journal Article Type: Article
• Acceptance Date: Mar 16, 2025
• Online Publication Date: Mar 17, 2025
• Deposit Date: Mar 21, 2025
• Publicly Available Date: Mar 21, 2025
• Journal: Results in engineering
• Electronic ISSN: 2590-1230
• Publisher: Elsevier
• Peer Reviewed: Peer Reviewed
• Article Number: 104657
• DOI: https://doi.org/10.1016/j.rineng.2025.104657
• Keywords: Wire arc additive manufacturing (WAAM); Steel; Mechanical properties; Microstructure; Defects
• Public URL: https://rgu-repository.worktribe.com/output/2755767