A review on mechanical properties of walls fabricated by wire arc additive manufacturing for aluminum alloys

With the increasing demand for lightweight and high‐performance components in industries such as aerospace, automotive, and marine, wire arc additive manufacturing has become an attractive manufacturing method due to its cost‐effectiveness and ability to produce complex geometries. This review provides an in‐depth analysis of the microstructure and mechanical properties of aluminum alloy walls produced using wire arc additive manufacturing. It explores the influence of various process parameters including voltage, current, travel speed, wire feeding rate, and shielding gas. The review emphasizes the importance of selecting suitable aluminum alloys, particularly highlighting the 5xxx series for their strong weldability and mechanical performance. Findings from recent research are compiled and presented in structured tables and figures to guide optimization of the process. Furthermore, the review identifies a need for further investigation into the 2xxx and 7xxx aluminum series, which offer higher strength but present challenges in terms of weldability and defect control. This work provides essential insights for improving outcomes in aluminum alloy manufacturing.