Research Progress in Shape-Control Methods for Wire-Arc-Directed Energy Deposition

Wire-arc-directed energy deposition (WA-DED) stands out as a highly efficient and adaptable technology for near-net-shaped metal manufacturing, with promising application prospects. However, the shape control capability of this technology is relatively underdeveloped, necessitating further refinement. This review summarizes the latest advancements in the shape control of WA-DED technology, covering four pivotal areas: the regulation of various process parameters, optimization of the deposition paths, control through auxiliary energy and mechanical fields, and synergy between additive and subtractive manufacturing approaches. Firstly, this review delves into the influence of deposition current, travel speed, wire feed speed and other parameters on the forming accuracy of additively manufactured parts. This section introduces control strategies such as heat input and dissipation management, torch orientation adjustment, droplet behavior regulation, and inter-layer temperature optimization. Secondly, various types of overlap models and techniques for designing overall deposition paths, which are essential for achieving desired part geometries, are summarized. Next, auxiliary fields for shape and property control, including magnetic field, ultrasonic field, and mechanical field, are discussed. Finally, the application of milling as a subtractive post-process is discussed, and the state-of-the-art integrated additive-subtractive manufacturing method is introduced. This comprehensive review is designed to provide valuable insights for researchers who are committed to addressing the forming defects associated with this process.