Abstract:
Wire arc directed energy deposition (WA-DED) is an effective method for the production and fabrication of large aluminum alloy components, offering advantages such as high deposition efficiency, excellent material utilization, and low production costs. However, challenges such as solidification cracks, hydrogen porosity, and inhomogeneous microstructures impede the broader adoption and application of aluminum alloys produced through WA-DED. The composite additive manufacturing process derived from WA-DED offers innovative approaches and support for the fabrication of high-performance aluminum alloy components. The recent advancements in WA-DED technology, interlayer-assisted WA-DED technology, and external field-assisted WA-DED technology for the preparation of aluminum alloys were reviewed. The effects of various processes on the microstructure and mechanical properties of the alloys were summarized. Additionally, it highlights existing challenges and outlines future directions for research in the field.