Influence of heat input and uniform temperature distribution during wire arc additive manufacturing process: a critical review

TY - JOUR

T1 - Influence of heat input and uniform temperature distribution during wire arc additive manufacturing process

T2 - a critical review

AU - Omiyale, Babatunde Olamide

AU - Ogedengbe, Ikeoluwa Ireoluwa

AU - Ogbeyemi, Akinola

AU - Olugbade, Temitope Olumide

AU - Zhang, Wenjun Chris

AU - Farayibi, Peter Kayode

N1 - Publisher Copyright: © The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2025.

PY - 2025/6

Y1 - 2025/6

N2 - The effect of heat input and uniform temperature on the surface quality of wire arc additive manufacturing (WAAM) components is crucial for producing defect-free WAAM components. However, in most WAAM technologies, the heat input significantly impacts the layer-by-layer molten pool deposits, potentially leading to defect formation if not properly controlled and optimized. In this paper, we critically review the effect of heat input, uniform temperature distribution, interlayer temperature, and heat input parameters on the microstructure and mechanical properties of WAAM components during fabrication. Based on our findings, wire feed speed and torch speed parameters significantly control heat input in the WAAM process. It is established that optimizing parameters with a lower input can result in a finer and more homogeneous morphology, which can substantially enhance mechanical properties in the fabricated components. To manufacture high-quality metallic components that meet industrial demands, there is a need to provide an evidence-based framework for understanding these critical issues in the WAAM process, ensuring that WAAM processes are thoroughly planned before use in design and fabrication, which is one main contribution of this paper.

AB - The effect of heat input and uniform temperature on the surface quality of wire arc additive manufacturing (WAAM) components is crucial for producing defect-free WAAM components. However, in most WAAM technologies, the heat input significantly impacts the layer-by-layer molten pool deposits, potentially leading to defect formation if not properly controlled and optimized. In this paper, we critically review the effect of heat input, uniform temperature distribution, interlayer temperature, and heat input parameters on the microstructure and mechanical properties of WAAM components during fabrication. Based on our findings, wire feed speed and torch speed parameters significantly control heat input in the WAAM process. It is established that optimizing parameters with a lower input can result in a finer and more homogeneous morphology, which can substantially enhance mechanical properties in the fabricated components. To manufacture high-quality metallic components that meet industrial demands, there is a need to provide an evidence-based framework for understanding these critical issues in the WAAM process, ensuring that WAAM processes are thoroughly planned before use in design and fabrication, which is one main contribution of this paper.

KW - Heat input

KW - Machine learning

KW - Process parameters

KW - Uniform temperature

KW - Wire arc additive manufacturing

U2 - 10.1007/s00170-025-15690-w

DO - 10.1007/s00170-025-15690-w

M3 - Review article

AN - SCOPUS:105005262156

SN - 0268-3768

VL - 138

SP - 2673

EP - 2695

JO - International Journal of Advanced Manufacturing Technology

JF - International Journal of Advanced Manufacturing Technology

IS - 7

M1 - 109471

ER -