Impact of metal transfer mechanism on characteristics and quality of layer deposition in wire additive manufacturing process: Part I – metal transfer mechanism

The significance of metal additive manufacturing for a large and complex structure is indispensable for the rapid growth of manufacturing sector. The transformation of welding technology into a controlled metal transfer brings lots of opportunity for the rapid pace of wire arc additive manufacturing. The current review is focused on the fundamental understanding of metal transfer mechanism from either self-adjusted wire or externally wire feeding system in different variants of heat sources. Primarily the molten metal transport form arc welding system is explored along with laser and induction melting of externally feeding wire. The direct fabrication of the product from complex alloy system through multi material deposition brings more opportunity in product design and manufacturing principle of the new component. Hence, the role of secondary wire is also explored to understand the complex material transport system. In general, the present work represents an independent effort to understand the strength and weakness of the wire-based system to further collaborate for the development of the wire-based additive manufacturing system.