j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5

Available online at www.sciencedirect.com

journal homepage: www.elsevier.com/locate/jmrt

Review Article

Review on effect of heat input for wire arc additive

manufacturing process

Nor Ana Rosli a, Mohd Rizal Alkahari a,b,*, Mohd Fadzli bin Abdollah a,c,
Shajahan Maidin c,d, Faiz Redza Ramli a,c, Safarudin Gazali Herawan e
a
Fakulti Kejuruteraan Mekanikal, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, Durian Tunggal, Melaka,
76100, Malaysia
b
Advanced Manufacturing Centre, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, Durian Tunggal, Melaka,
76100, Malaysia
c
Centre for Advanced Research on Energy, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, Durian Tunggal,
Melaka, 76100, Malaysia
d
Fakulti Kejuruteraan Pembuatan, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, Durian Tunggal, Melaka,
76100, Malaysia
e
Industrial Engineering Department, Faculty of Engineering, Bina Nusantara University, Jakarta, 11430, Indonesia

article info abstract

Article history: Wire arc additive manufacturing (WAAM) is steadily increasing with significant research
Received 31 October 2020 work are underway. The ability of WAAM to manufacture a large-scale product at a lower
Accepted 1 February 2021 cost and shorter lead times has increased its development. The efficiency or potential of
Available online 8 February 2021 WAAM to become a new lead in the additive manufacturing industry is believed to be
realized by a few factors. High efficiency and performance require a higher metal deposi-
Keywords: tion rate, which implies higher heat input that negatively affects the manufacturing pro-
Systematic literature review cess. This paper review works for factors associated with heat input on the WAAM process.
Wire arc additive manufacturing The factor affecting these properties were explained to identify the optimized WAAM
Micro plasma arc welding process in terms of heat input. The paper focuses on the impact of heat input on the
Additive manufacturing macrostructure, microstructure and mechanical properties of the parts deposited in the
3D printing WAAM process. This review also discussed the effect of heat input used by eight different
types of arc welding technologies, with appropriate use of wire materials. The study also
highlights that heat input affected the microstructure of the WAAM, causing significant
changes in grain structure, grain size and pore area percentage. Besides, it can be suggested
that grain structure has a strong influence on the WAAM materials’ mechanical properties.
© 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC
BY license (http://creativecommons.org/licenses/by/4.0/).

* Corresponding author.
E-mail address: [email protected] (M.R. Alkahari).
https://doi.org/10.1016/j.jmrt.2021.02.002
2238-7854/© 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY license (http://
creativecommons.org/licenses/by/4.0/).
2128 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5

are the deposition rates are significantly higher, and unlimited

1. Introduction build envelope in the shortest time [4,8]. In the wire-based
process, the wire is used to manufactured metal compo-
Additive manufacturing (AM) is a promising technique that nents instead of powder and melted with a laser, electron
allows the manufacturing large, complex geometry and fully beam or an electric arc. The process involves such as wire arc
dense metal objects by layer by layer manufacturing tech- additive manufacturing (WAAM), wire and laser additive
nique. AM offers a significant advantage over traditional manufacturing (WLAM) [7], electron beam freeform fabrica-
manufacturing, and has transformative potential on various tion (EBF3) and laser-engineered net-shaping (LENS) [9].
industrial applications [1]. The conventional manufacturing Among these three energy sources, the laser is the most
technique often required a considerable number of machining common due to its precision or higher accuracy in shaping
and cannot fulfill the continuously increasing requirements. parts. However, this requires a low energy efficiency in these
The motivation for using AM is the need to automate ma- applications (2%e5%) [10]. The electron beam is another
chines movement, minimise waste material, reduce energy popular energy source for these applications due to its slightly
consumptions, and improve material efficiency [2,3]. Other higher energy efficiency (15%e20%). However, it requires a
than that, the ability of AM to create three-dimensional and high vacuum working environment [11]. Santos et al. [12] and
producing free form components on a layer by layer basis is a Wanjara et al. [13] point out that these two energy source use
major driving force for breakthroughs [4]. The AM of metal very high energy densities, resulting in excellent dimensional
structures is divided into powder-based and wire-based [2]. properties in printed parts, but has several downsides such as
In powder-process, the metallic powder melting using a low deposition rate, high cost, and limited components size
laser beam or an electron beam such as selective laser melting [14,15].
(SLM) [5], laser metal deposition (LMD) [6] and electron beam Currently, both academia and industrial players have
melting (EBM) process. However, the deposition rate is low shown great interest in the potential of WAAM. WAAM uses
despite a very high precision of dimensional tolerance [4,7]. an electric arc as an energy source and a solid wire as a
The use of powder as feedstock resulted in the formation of feedstock material. It employs either gas metal arc welding
defects such as pores that may reduce the part’s structural (GMAW), gas tungsten arc welding (GTAW) or plasma arc
integrity. Compared to powder-based, wire-based advantages welding (PAW). WAAM gains more and more attention due to

Fig. 1 e Classification of metal AM technique.

 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5 2129

alloy. As WFS increases, the molten pool of thin becomes

unstable, and the impact of arc force leads to a low quality of
forming [22]. Dinovitzer et al. [23] argued that the wire feeding
process’s significant is the residual stresses and distortion
produced during the AM process. Other than that, distortion
and residual stress can affect geometric precision and degrade
mechanical properties components [24]. These are caused by
excessive heat input of energy, high deposition rate, and a
large temperature gradient. The literature has identified
various factors that encourage the heat input on the consis-
tency of the WAAM pieces. The most crucial factor is the re-
searchers are looking forward to reducing the heat input and
expected to bring the excellent quality of fabricating parts in
terms of macrostructure, microstructure, and mechanical
properties. This review has been carried out through a sys-
tematic literature review process using PRISMA (Preferred
reporting item systematic reviews and meta-analysis) state-
ment approach. The aim to objectively synthesize empiric
Fig. 2 e Publication trends of WAAM process.
literature on the impact of heat input on the macrostructure,
microstructure and mechanical properties of the parts
its potential to reduce cost and material waste, besides deposited by the WAAM process.
shortening the lead times. The advantage through its ability to
create neat-net shaped and the deposition rates are signifi-
cantly higher. The automobile and aerospace industry is one 2. Wire arc additive manufacturing process
of the driving force industries that focuses on the application
of WAAM in lightweight construction using titanium or The 767 articles dedicated for WAAM based on search string
aluminum alloy as a filler material [16e18]. As shown in Fig. 1, “wire arc additive manufacturing” OR “WAAM” implied that
the metal AM technique classification indicates that they can there are two primary journal databases e Scopus and Web of
be divided into powder-based and wire-based raw materials. Science (WoS). The records after duplicates removed are 492
WAAM is superior in producing a large-scale product articles and limited to “Engineering field”, “article” and “En-
compared to other AM methods due to its high efficiency and glish” language Based on the year, the number of published
low cost of raw materials [19]. Moreover, the cost of metal wire items will increase significantly, as shown in Fig. 2. It indicates
as raw material is roughly 10% of powder raw material cost. that WAAM is gaining interest in the manufacturing industry
Thus, the WAAM process produces high deposition at a low currently.
cost, making it highly preferable to manufacture large-scale Generally, the research more focusing on how to make this
products using expensive materials [20]. However, its high process is reliable with industry and acceptable to be used for
efficiency is attributed to the high heat input and wire feed broader usage. There are five main disadvantages of WAAM as
rate. According to Tabernero et al. [21] the WAAM technology, highlighted by Pan et al. [25]. The WAAM received less atten-
regardless of welding technology, achieves high deposition tion due to high heat input, poor accuracy and surface finish, a
rates of up to 5 kg/h on stainless steel or 2.5 kg/h on Tie6Ale4V solid layer cannot be filled to form a smooth surface, an

Fig. 3 e WAAM research hotspot [26].

2130 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5

Table 1 e Some recent studies on heat input of WAAM process.

Author Specific area of improvement Arc welding Material
Greebmalai et al. [28] Produce laminate wall and heat induce the effect of heat condition on the Double pulse (DP) GMAW ER 5356
laminate dimension
Lee et al. [20] Optimize metal deposited using the Gaussian Process Regression (GPR) CMT STS 316L
Yuan et al. [29] Practical studies by fabricating metallic parts with overhanging features Multidirectional CMT ER 70S-6
Wu et al. [30] Impact of heat accumulation on arc characteristics and metal transfer GT-WAAM Tie6Ale4V
behaviour

immature CAD system to part AM using arc welding, and lack the metal deposited using the Gaussian Process Regression
of integration for process monitoring and control during (GPR) method utilizing CMT-based AM.
deposition. As the years growing, a lot of improvement has In the CMT arc welding process, the wire feed rate is pro-
been made on this process and the number of research is portional to the current and voltage; therefore, an increase in
increasing tremendously. The process’s main advantage leads the wire feed rate indicates increased heat input. However,
to numerous researchers to improve the process in terms of because of additional post-processing required to remove
quality, properties, and ability to build complex shape. Liu redundant surfaces, the performance is reduced. Yuan et al.
et al. [26] had summarized the WAAM research hotspot and [29] proposed a practical study by fabricating metallic parts
future development as shown in Fig. 3. with the overhanging feature using multidirectional CMT-
based WAAM. As a result, welding bead geometry degenerates
with an increase in WFS and combined effects of reduced
3. Heat input on WAAM process surface tension, longer metal freezing time and increased
weld bead volume. Wu et al. [30] study the impact of heat
The review’s scope is limited to the effect of heat input on accumulation on arc characteristics and metal transfer
sample manufactured by the WAAM process. It primarily behaviour of Tie6Al-4V materials in WAAM. Due to the spe-
focusses on the most significant arc welding used as a func- cific thermal dissipation and the building height, a significant
tion of heat input. The heat input is the relative measure of the difference in temperature variation occurs. The findings show
transferred energy per weld unit length [27]. One of the critical that the stability of the heat on the deposition has proved to be
parameters involved during the preparation of welding pro- very important. Besides, the parts manufactured by WAAM
cedure requirements is the heat input. The cooling rate, which display anisotropy in tensile properties, which attributes to
is the primary factor in deciding the weld’s final metallurgical strengthening the grain boundary between the horizontal and
structure and the heat-affected region, also influences the vertical direction [21,31,32].
values. Heat input is also one of the variables used to assess The rising market demands the WAAM method for quality
heat-affected zone (HAZ) grain size and width. These welding and efficiency to improve productivity and manufacturing
parameters also serve as the key factors influencing the cost reductions. Based on the above literature, the increasing
embrittlement of welding joints. Low heat input is the most interest in improving the quality of parts produced by the
common welding parameter chosen for industrial applica- WAAM process and seemed timely to summaries the results
tions due to its ability to create refined microstructure, less of the available research.
stress, and distortion of welding.
In WAAM, the high deposition rate and efficiency is the
main advantage of this process. This expense of extensive 4. Systematic review methodology
heat input and severe damage to deposited layers. Several
researchers have experimented with heat input on the con- The review was conducted using the SLR methodology out-
struction of WAAM based metal components, as summarised lined by Moher et al. [33]. The PRISMA statement developed
in Table 1. Greebmalai et al. [28] used the double pulse current the guideline for a systematic review. The systematic review
(DP) GMAW to form the laminate wall due to a preliminary study analysis is based on the key research issue: what is the
experiment that suggested that the DP-GMAW had a more effect of heat input on the WAAM process? The literature
uniform bead. The result shows that the heat input induces search was performed using the Scopus and Web of Science
the effect of the heat condition on the laminate dimension. (WoS) databases, using keywords and phrase search functions
The double pulse did not have a noticeable impact on the bead as well as the Boolean operator (OR, AND) to identify relevant
size; however, to minimize the laminate sloop, the lowest heat papers for the studies. The search string containing the search
condition should be used to build up. Lee et al. [20] optimize words, as shown in Table 2 in the title-abstract-keywords.

Table 2 e The search string.

Databases Keywords used
Scopus TITLE-ABS-KEY ((“wire arc additive manufacturing” OR WAAM”) AND
(“heat input”))
Web of science TS ((“wire arc additive manufacturing” OR “WAAM”) AND “heat input”)
 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5 2131

Fig. 4 e Flow diagram of the review process.

Next, the journal was selected according to the eligible 5.1. Publication trends
article in the domains of mechanical engineering. The publi-
cation is included regardless of the period and journal quality The publication considered is of academic articles with
rating. Here, other types of publications are excluded the re- empiric data. Table 3 shows that 6 publishers have more than
view articles; these are, novels, films, books, chapters in books two relevant studies. International Journal of Advanced
and conference papers. Only the empiric articles have been Manufacturing Technology, Journal of Materials Processing
exclusively selected because the extraction of data for a sys- Technology and Metals contributed the largest number of
tematic review is based on original works rather than on in- relevant studies and a similar number of contributed works.
terpretations of results [34]. Table 2 describes the inclusion The trends of annual publications on the heat input of the
criteria of this study. WAAM process have increased significantly within a year, as
Based on the database searching, it yielded a total of 123 shown in Fig. 5. Starting the year 2015, the number of publi-
articles from Scopus and WoS. After duplicating the article, it cations have since increased remarkably until recent. The
remained 83 articles to be reviewed the title and abstract and expectation of increasing is nonetheless and year 2021 also
excluded the works that did not fit the inclusion criteria pre- there already have 2 peers reviewed academic article for this
sented. The process led to the exclusion of 29 articles. The current study.
main reason is the article not focusing on the heat input of the
WAAM process. Afterwards, the remaining article was ana-
lysed to evaluate their eligibility accordance to the inclusion
criteria presented. This process accompanies the final inclu-
sion of 38 articles eligible for the review. The flow diagram of
Table 3 e Publishing journals.
the review process as illustrated in Fig. 4, which summarize
the process. Source title Number of
articles
International Journal of Advanced 5
5. Descriptive analysis of literature Manufacturing Technology
Journal of Materials Processing Technology 4
Materials 5
The observation presented comprehensively evaluated the Materials and Design 3
trends of publication and analyzed the types of arc welding Metals 5
used in the empirical studies to provide a critical literature Welding in the World 3
review. Others 13
2132 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5

25 VP-CMT
23
Tandem GMAW

Types of arc welding

20 Super-GTAW
Number of articles

Pulsed-PAW

15 PAW

GTAW

10 GMAW

CMT

5
5
0 2 4 6 8 10 12 14
3 Number of arc welding
2 2 2
1
0 Fig. 6 e Types of arc welding.
2015 2016 2017 2018 2019 2020 2021
Year

Fig. 5 e Number of articles published.

6. Analysis effect of heat input in WAAM

process
5.2. Overview of recent studies
In this section, the discussion focuses on three main effects of
The selection of arc welding been used is important in the heat input: namely macrostructure, microstructure, and me-
WAAM process. Arc welding act as a melting source or heat chanical properties. The effect of heat input described in this
source to melt the wire and the substrate. Commonly, three section and a summary provided at the end of each theme
types of welding are mainly used in WAAM: PAW, GTAW and classification.
GMAW. However, regardless of their capability many re-
searchers try to explore another way to produce 3D metal 6.1. Macrostructure
parts with acceptable geometrical accuracy. As shown in Fig. 6
the most number of arc welding use is the CMT process. CMT Macrostructure is defined as the external structure of the
process is a newly developed method gaining attention as an sample deposited. The influence of the heat input on the ad-
alternative heat input for the WAAM process and character- ditive component’s macrostructure, as shown in Table 5. The
ized by its low heat input, low dilution cladding and high heat input thereby affects the macrostructure sample pro-
deposition rate [35]. Its application in the WAAM of aluminum duced by the WAAM process. Xiong et al. [54] characterise the
alloy has attracted considerable attention. Second popular of macrostructure of the sample impact of the different heat
high-interest arc welding is GMAW due to increased deposi- inputs. As a result, the increase in heat input increased the
tion rates, material efficiency >90% and the almost unlimited ratio of wire feed to deposited velocity.
space available [36]. Two studies are using Tandem GMAW as It led to metal deposition per unit length. However, the
recorded, which looks like GMAW, but it works with two-wire difficulty is to reduce the heat input to the substrate and in-
are fed into the molten pool simultaneously and can double crease the deposition rate. Moreover, the wire feed rate is
the efficiency of the conventional process. However, as the directly coupled to the heat input. Increased heat input will
efficiency is increasing, it is accompanied by high heat input. enhance the excessive form of molten metal and regulate the
As a result, the melting energy and more challenging to con- bead geometry during WAAM. The bead geometry has a great
trol. Next, VP-CMT, super GTAW and pulsed PAW have one chance in the thickness of the thin wall and the thickness of
study, which is new development by researchers trying to the layer. Wang et al. [55] found that the low equivalent heat
overcome the issue faced by the WAAM process. input has a uniform surface without the welding pool over-
A total of 38 studies looked at the effect of heat on the flowing and collapsed. As shown in Fig. 7, the macrostructure
macrostructure, microstructure, and mechanical properties of shows no noticeable distortion and incomplete fusion defects
the WAAM process. The analysis can be broken down into and hot cracks are not found.
three key categories: improvement, process parameters, and Su et al. [48] and Li et al. [49] used CMT-based WAAM
development. The enhancement is in terms of fabricating technology to manufacture AleMg alloys under different heat
approach, arc welding forms, and wire material being used. inputs by adjusting wire feed speed and travel speed. Efficient
The study that identified the optimum process parameters wall width shows an increasing trend under various heat
aims for better surface finish, microstructure, and mechanical input forms, as shown in Fig. 8, increasing wire feed speed and
properties. Besides, the study also provided a relatively un- decreasing travel speed. Li et al. [49] found that the layer’s
derstanding of the relationship between input and output thickness and height gradually increased with an increase in
process parameters. Table 4 summarized all the studies the heat input.
involved. Wang et al. [40] proposed that the relationship fulfills the
two functions between deposited thickness and heat input
Table 4 e Area of studies.
No Author Year Area of study Specific area of study Arc welding
1 [37] 2020 Improvement-fabricating approach Suggested the building strategy of an aluminum alloy via polarity sequence with alternating current. CMT
2 [38] 2016 Process parameter Deposited Tie6Ale4V thin wall by an optimized weld wire feed of Pulse-PAW which heat input Pulse-PAW
gradually decreased layer by layer
3 [39] 2020 Process parameter Deposited AleCueSn as raw material with different heat input CMT
4 [40] 2020 Improvement-Arc welding Fabricate AleCueSn alloy using single and double wire CMT
5 [41] 2020 Improvement- Wire material Fabricate 1.6 mm Ale7Si-0.6 Mg alloy wire to improve forming efficiency CMT
6 [42] 2020 Improvement- Wire material Deposited Superduplex filler wire to create walls with different heat input CMT

j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5
7 [43] 2020 Process parameter Present findings on hydrogen dissolution in solid aluminium and hydrogen consumed to form porosity Pulse-GMAW
along with its distribution as a function of heat input and interlayer temperatures in WAAM 5183 CMT
aluminium alloy
8 [44] 2018 Process parameter Investigate the effect of arc modes fabricated by CMT, CMT advanced and CMT pulse. CMT
9 [45] 2020 Improvement-Arc welding Fabricated using Super Tig welding by Inconel 625 and observed the influence of heat input along with Super GTAW
layering strategies
10 [46] 2020 Improvement-Wire material Fabricate two titanium alloy blocks using Hot WAAM GTAW
11 [47] 2019 Improvement-Wire material Fabricate duplex stainless-steel block and study the relationship between heat input, interlayer GMAW
temperature, thermal cycle, and microstructure
12 [48] 2019 Process parameter Investigate the deposition under different heat input by adjusting wire feed speed and travel speed CMT
13 [49] 2019 Improvement-Wire material Adopted hot wire in WAAM process to reduce heat input and refine columnar grains GTAW
14 [50] 2018 Improvement-Use Tandem Wire Use tandem wire and arc to control and minimizing the crack Tandem GMAW
15 [51] 2017 Process parameter Investigate the effect of alternating current TIG on AL WAAM GTAW
16 [52] 2018 Development-cooling system Introduced the process active cooling system based on thermoelectric cooling technology Tandem GMAW
17 [53] 2016 Improvement-Wire material Develop Nickel Aluminium component using the WAAM process GMAW
18 [54] 2015 Process parameter Study forming characteristics of multi GMAW layer single pass parts GMAW
19 [55] 2021 Improvement-Arc Welding Deposited thin wall component of AZ31 magnesium alloy using modified CMT. CMT
20 [56] 2021 Process parameter Study the effect of wire size on the limitation of deposition rate and bead shape PAW
21 [57] 2020 Process parameter Deposited mild steel using GMAW based WAAM to understand the primary process variable and their GMAW
influence in the final component.
22 [58] 2020 Process parameter Fabricated minimal heat input per layer employed on CMT-WAAM of precipitation hardening Ni-based CMT
alloy Inconel 718.
23 [59] 2020 Development-controlled short circuiting Develop high performance controlled short circuiting metal transfer process with AleMgeMn alloy. GMAW
24 [60] 2020 Process parameter Proposed a heat input condition controls system which control from the welding power source GMAW
according to the temperature of the building structure
25 [61] 2020 Improvement-Adding an external filler wire Proposed external wire fed directly into an arc to consume arc energy GMAW
26 [62] 2020 Process parameter Different process cooling strategies are weighed up regarding efficiency, the impact of the process, and GMAW
microstructure of processed steel.
27 [63] 2020 Improvement-Wire material Development of a novel TIG hot wire process for AM of the metallic component and enables significant GTAW
interest in melting performance with simultaneously reduced heat input.
28 [64] 2020 Improvement-Arc welding Manufacture high strength structural steel parts using robotic CMT. CMT
29 [65] 2020 Process parameter Study WAAM of AlMg5Mn alloy and investigate the correlation of energy input and resulting GMAW
temperature-time regimes
30 [66] 2020 Process parameter Revealing the relationship between microstructure and mechanical properties of WAAMed AZ31 CMT
material deposited using CMT as a heat source.
31 [67] 2020 Development- New structure of welding torch Develop the new structure of welding torch to reduce heat input by proposed a compulsively constricted GMAW
WAAM technology

2133
(continued on next page)
2134 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5

Arc welding and between layer height and heat input. Based on the target
wall thickness, the heat input is selected, and the distance of
the layer height is determined. Li et al. [52] minimise heat
VP-CMT input through the WAAM hot-wire process and found a sig-

GMAW

GMAW

GMAW
PAW
CMT

CMT
nificant difference in appearance caused by the molten pool’s
size. Four test groups (H-0, H-60, H-80, H-100) were produced
with a heat input of 207 J/mm, 181 J/mm, 142 J/mm, and 137 J/
Implement short arc welding regimes and respectively reduced welding process. The efficient strategy

Analyzed three deposition strategies which the energy and deposition ratio used are varied and studied
Reciprocating the deposition of 30 layers for 316 SS by CMT and comparing the morphology, effective

Investigate the effect of heat input on the mechanical properties and microstructure of the AlCu6Mn

Conduct an experiment using Box Behnken design of RSM. This study has careful considerations of

mm, respectively. As shown in Fig. 9, periodic bulges from

partial enlargement on all four component surfaces. Never-
theless, the surface with heat input 207 J/mm produces a

Investigate the effect of heat accumulation during deposition by performing comprehensive

much smoother surface than the heat input group 142 J/mm
as the layer’s height decreases. The four-part height and
by adjustment of the contact tube to work piece distance during the welding process.

width changed drastically from 40 mm to 80 mm and

8.5 mme5.5 mm, respectively, when the arc heat input grad-
ually reduced. It is because of two main factors affecting grain
growth during the AM process: temperature gradient and so-
experimental and numerical study on multi-layer deposition STS316L
deposition rate per power, microstructure, and deposition properties.

lidification speed.
Proposed on-line vortex cooling powered to reduce common defect

As a result, the lower the heat input, the molten pool does
Specific area of study

not have enough time to spread before solidification, and the

ratio of width to height tends to be smaller. The molten metal
pool is much more convenient to spread when increasing the
heat input to 519 J/mm, where the metal’s viscosity decreases.
droplet transfer, heat input and shaping coefficient.

However, once the cooling power matches the heat input, the
difference in heat dissipation between the upper and lower
layer can be eliminated and help to achieve the beads’
consistent geometry. In the present contribution, Klein [37],
proposed improvements to the fabricating approach during
the WAAM prosses through polarity variance sequenced.
Research by Ayarkwa et al. [51] has shown that alternating
current is an alternative to the linear wall formed. Based on
after WAAM deposition

the result, heat input is the main control factor for wall ge-
two cooling strategy

ometry. Other researchers, Hosseini et al. [47] found no sig-

nificant changes in the production block with low and high
heat input, but that the total number of passes reduced. As
mentioned by Wang et al., the CMT twin process’s surface by
single and double wire alloy AleCueSn is slightly smoother
and more uniform, as shown in Fig. 10. The result obtained,
dual wire heat input was lower at the same wire feeding speed
than the single wire wall [40]. The resulting product is more
stable than a single wire because of the interaction between
the two arcs of dual wire, and the molten pool created is more
Improvement-Fabricating approach
Development-contact tube to work

uniform.
In summary, the macroscopic macrostructure was closely
Area of study

related to heat input, speed, wire feed rate, solidification rate,

interlayer temperature, and bead geometry. The central
aspect of being covered is to reduce the heat input, to ensure
Process parameter

Process parameter

Process parameter

Process parameter

Process parameter

geometrical accuracy, and to increase the rate of deposition.

Variation in the control of bead geometry when optimising the
parameter includes heat input, travel speed, and wire feed
speed.

6.2. Microstructure
Table 4 e (continued )
Year
2019

2019

2020

2020

2020
2020

2020

Using AM technologies to fabricate components will experi-

ence complex cyclic thermal history. Considering the pro-
Author

cessing and properties related to microstructure is a

[68]

[69]

[70]

[71]

[72]
[73]

[74]

requirement in creating a database for processing of AM ma-

terials. Due to the different heat input and cooling rates, the
WAAM process’s microstructure underwent a significant
No
32

33

34

35

36
37

38

change. The heat input during the processing of WAAM

 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5
Table 5 e Process parameter affecting on macroscopic macrostructure.
Author Arc Wire material Heat input (J/mm) Macroscopic
Welding
[54] GMAW Copper coated steel 379e980 The forming appearance studies with larger currents which shows instability and the overflow of the
molten pool produced.
The optimum current for good appearance is between 100 and 180 A.
[40] Tandem GMAW 2325 Al 465 Due to the molten pool, the ratio width to height tends to be smaller and does not have enough time to
491 spread before solidification.
519 The viscosity of the material decreased, and the molten pool was much easier to spread.
[41] GTAW 5556 Al 674e834 Increase the heat input by 20%, increase the bead’s width corresponding to the decrease in the height of
the layer.
[53] GTAW Ti-6.5Al-3.5Mo-1.5Zr-0.3Si (Hot wire) H-0 ¼ 207 Layer height increases from 0.9 to 1.7 mm, while the width decreases from 8.5 to 5.5 mm.
H-60 ¼ 181
H-80 ¼ 142
H-100 ¼ 137
[43] CMT Al-Mg (ER 5356) 141.568e242.080 Different heat input showed increasing width wall patterns with higher wire feed rate.
[47] GMAW Type-2209 (duplex) stainless steel 500e800 High heat input, high temperature reduced a total number of passes.
[44] CMT 5183 aluminum 157.8 All three mode has a good surface appearance, but CMT þ A show the smoothest top surface.
CMT þ A 165.3
CMT þ P 185.4
[41] CMT Ale7Si-0.6 Mg 73.13e470.95 The average layer height increases gradually and increasing thickness while increased heat input
[40] CMT AleCueSn Single wire ¼ 143.54 Double wire produces more uniform and surface more even.
Double wire ¼ 109.0
[39] CMT AleCueSn 30e150 Thickness and layer height gradually increases with increasing heat input. Width of molten pool
improves resulting increase in thickness.
[37] CMT AlMg4.5Mn (ML5183) 56e67 Surface quality improves when controlling heat input during pulse repetition sequence.
[55] CMT AZ31 Low heat input Uniform surface without overflowing and the collapse of the welding pool

2135
2136 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5

welding pool’s heat input. The grain size for microstructural

studies shows in the inner layer region and the interlayer re-
gion as shown in Fig. 13. The sample microstructure indicates
a gradual increase in grain size as the wire feed speed in-
creases, constant travel speed and heat input increases.
However, though travel speed increases and other parameters
remain constant, the heat input decreases and faster solidi-
fication slows down the rate of grain growth. Under different
heat inputs, the pores’ propensity to form is mainly attribut-
able to other heat inputs, contributing to various degrees of
overheating of the molten pools [39]. The leading cause of the
lack of fusion pore is excessive heat input [46].
Wang et al. [40] found that a single wire’s grain structure is
predominantly isometric crystals with small amounts of
mixed columnar crystals. Still, walls are all isometric crystals
Fig. 7 e Macrostructure of CMT-WAAM thin well for grains of double wire. The double wire process’s heat input
component [55]. under the same amount of wire feeding is just half of the
single wire heat input. Therefore, the grain size decreased
dramatically, and evenness increased, as seen in Fig. 14.
affects the thermal gradient, nucleation, and grain growth
The use of cold metal transfer (CMT) in WAAM has gained
rate [52]. The process concerning the microstructure is spec-
significant interest. The CMT process is often used for WAAM
ified, as shown in Table 6. Usually, the microstructure diagram
based on the filler wire reciprocating motion and aluminium
divides into three regions: stable zone, unstable zone, and
short-circuiting or dip transfer [35,75]. CMT technology allows
stable and unstable region interface. All three-zones have
significantly lower heat input, high cladding efficiency, and no
shown in the basket-weave microstructure, and the main
spatter. Derekar et al. [43] manufactured samples using two
reason for this organisation is due to frequent thermal cycling
different arc welding modes; CMT and pulsed-MIG. The result
during the cycle of Hot-WAAM. Li et al. [49] found that the a-
shows the opposite effect of heat input between those two arc
phase width decreased from top to bottom of the layers
mode. Under high heat input of the CMT technique, the
because of the relatively calm substrate at the beginning as
porosity increases relative to low heat input, and the result
shown in Fig. 11. Moreover, reducing the heat input also
sustained at two separate interlayer temperatures or two in-
reduced the width a and became thinner in size.
door periods. However, the pulsed-MIG method revealed that
As the heat increases, the molten metal’s solidification rate
little heat input contributed more porosity to the total volume
decreases, so the grain’s growth follows the temperature
compared to the high heat input sample.
gradient direction, as shown in Fig. 12. Cheepu et al. [45] reveal
The pore size is divided into three ranges; small
that based on observation of layering structure, the micro-
(0.11e0.20 mm), medium (0.21e0.30 mm), and large (greater
structure of deposits at a high heat input of 2.1 kJ/mm dis-
than 0.31 mm). As a result, the pulsed MIG showed a higher
closes the formation of grains with columnar crystals and vast
pore content than the CMT and a small majority size range for
dendrite arm space. As the heat input decrease to 1.1 and
both processes. However, the pulsed MIG showed a higher
0.7 kJ/mm, the microstructure change to fine grain crystal str
percentage of medium and large pores than CMT. Fang et al.
ucture and is homogeneous throughout the deposits.
[44] used three different welding arc modes, including CMT,
Wang et al. [56] fabricated 50 layers using appropriate CMT
CMT þ Pulse and CMT þ Advanced to deposit the 5183 Al wire
characteristics parameter. The microstructure shows fine
in other heat inputs. The highest CMT þ P heat input con-
columnar dendrite grains grow from the bottom to the top of
tributes to the largest pore formation and columnar grain
deposited layers. Su et al. [48] and Wang et al. [39] reported the
output based on the findings. The large columnar grain that
behaviour of grain growth rate due to an increase in the
formed prevents the escape of pores from the molten liquid.

Fig. 8 e Cross-setional appearance under different heat input; (a) Macroscopic of typical thick-walled [48] and (b) the top
surface of alloy [41].
 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5 2137

Fig. 9 e Four thin-walled square component manufactured by hot wire -WAAM different heat input [49].

Between these three arc modes, CMT and CMT þ A consist of form the b-phase. Thus it resulted in a martensite structure
the interlayer fine grain region and the layer columnar grain that is harder than the a phase but also less ductile and more
zone and the CMT þ A sample formed the smallest pore area. brittle after retained with rapid cooling. From the micro-
Lervåg et al. [42] used super duplex stainless steel wire for the structural study, the combination of an increasing percentage
WAAM process to create a wall with different heat inputs. No of alternating current and heat inputs causes the cooling rate
intermetallic phase was found within the heat input range to slow down and the grains to grow longer [48]. The influence
(0.4e0.87 kJ/mm) due to low inter pass temperature and high factor of a crack is a microstructure that is substantially
Ni content in the wire applied. Increased heat input can be determined during deposition by the heat input. This is
related to the coarsening of the microstructure. Adjusting the mentioned by Gu et al. [50] in their work on reducing ternary
component design, heat input, and shielding gas are recom- alloy cracks during the deposition of WAAM. The higher the
mend for faster cooling speeds. heat input during the deposition, the more extended period of
Lin et al. [52] deposited Ti-6Al-4V thin wall with optimised growth, will improve grain growth. However, higher heat
welding wire feed pulsed plasma arc additive manufacturing input is undesirable as it could be harmful alloys with longer
(PPAM), which gradually decreased the heat input layer by freezing time due to more time for generation, floating, coa-
layer. Heat input has a significant influence on thermal lescence, and growth defects. It further raises the cracking
gradient, nucleation, and grain growth rate. As a result, in the propensity considerably.
PPAM process, a small deviation of average heat input restricts In summary, the WAAM sample’s microstructure under-
the growth of prior b-grain and a-lamellar, so the micro- went a significant change due to the influence of the heat
structure refined. Ding et al. [53] discussed the effect of heat input resulting in changes in grain structure, grain size, and
input on the microstructure of additively manufactured NAB pore area percentage. By controlling the process parameter
wall structure. The increasing heat input of 1114J/mm is suf- such as wire feed speed, travel speed, and heat input resulting
ficient to raise the temperature above the eutectic point and to in the molten metal’s solidification rate, which affects the

Fig. 10 e Surface macrostructure; (a) Single wire, (b) double wire [40].
 2138
Table 6 e Effects of process parameter on microstructure and mechanical properties.
Author Arc Welding Wire material Heat input (J/ Microstructure YS (MPa) UTS (MPa) EL (%)
mm) observation
[53] GMAW NAB, AX-CuAl8Ni6 653e1114 Precipitation a phase during 324e350 642e667 27e29
the heat treatment
enhanced the mechanical
properties
[51] GTAW 5556 Al 674e834 Slow down the cooling rate e e e
and allow more time for the

j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5
grain to grow.
[50] Tandem GMAW AleCu and AleMg 170.1, 251.4 Transit from columnar to e e e
equiaxed grain to equiaxed
dendrites.
[49] GTAW TC 11 H-0 ¼ 207 Width of the a phase H - 806 ± 41 873 ± 23 988 ± 33 23 ± 2.5
H-60 ¼ 181 reduced V - 810 ± 23 9.17 ± 1.8
H-80 ¼ 142 H-0, H-60, H-80: Coarse H - 786 ± 21 871 ± 28 970 ± 5 19.9 ± 6.6 10.7
H-100 ¼ 137 columnar grain V - 887 ± 5 ± 0.4
H-100: Short columnar grain H - 774 ± 25 863 ± 27 956 ± 15 20 ± 6
and equiaxed V - 810 ± 27 12.6 ± 0.5
H - 835 ± 3 929 ± 5944 ± 9 12.6 ± 2.1 12.8
V - 840 ± 11 ± 2.4
[48] CMT AleMg (ER 5356) 141.568e242.080 Achieved modification 119-131 (location1) 252-262 (location1) 26.4%e23.3%
columnar grain to equiaxed 128-141 (location 2) 249-259 (location2) 24.4%e21.6%
[47] GMAW 2205 SS 500e800 Austenite fraction (mostly e e e
grain boundary)
[46] GTAW Tie6.5Ale2Zre1Moe1V 315 Hight porosity, low- e e e
temperature gradient-
Equiaxed b grain
[45] GTAW Inconel 625 700e2100 2100 J/mm e Columnar e e e
crystal
1100e700 J/mm e Crystal
structure
[44] CMT 5183 aluminum 157.8 Smaller columnar grain e H-297.9 e
V-280.5
CMT þ Advance 165.3 Smaller columnar grain e H-296.9 e
V-291.8
CMT þ Pulse 185.4 Coarse columnar grain e H-284.9 e
V-270.2
[43] Pulsed GMAW 5183 aluminum 158e351 Low heat input, porosity e e e
increase and pulsed GMAW
produce more pore
compared to CMT. The
majority size of the pore is
smaller.
CMT 140e345 Porosity increase while e e e
higher heat input
[42] CMT Superduplex SS 0.87 kJ/mm, No intermetallic phase was 160 and 100 MPa for vertical and horizontal e e
0.54 kJ/mm, found
0.40 kJ/mm
[41] CMT Ale7Si-0.6 Mg 73.13e470.95 a-Al dendrites in the ACZ 310 ± 5.5 354.5 ± 7.5 6.3 ± 0.7%
became coarser, the
number of dendrites
decreased, and the
secondary dendrite arm
spacing (SDAS) increased
gradually. After amplifying

j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5
the ACZ, the fine-needle-
like or short-bar-like Fe-
phase was observed.
[40] CMT AleCueSn Single Single wire with higher heat e e e
wire ¼ 143.54 J/ input e Mixed isometric
mm crystals and a small number
of columnar crystals
Double Double wire with half heat 420 490 12%
wire ¼ 109.0 J/ input that single wire e All
mm isometric crystals
[39] CMT AleCueSn 30e150 30 e All isometric crystals 425 470 9%
60/90/120-Mixture of
isometric and columnar
[38] Pulse-PAW Tie6Al-4v Decrease 0.75 kJ/ Varying prior columnar 909 ± 13.6 988 ± 19.2 7 ± 0.5
cm step by step large b grains from the
8.23 kJ/cm e substrate to top.
5.19 kJ/cm Columnar b grains- one to
three deposited layers
Columnar b grains
epitaxially grow in a
different direction after four
layers.

2139
2140 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5

properties of the sample. Fine equiaxed grains reduce the

solidification cracking and improve toughness, ductility and
strength. On the other hand, large columnar grains can cause
anisotropy of the mechanical properties. Hence, it is essential
to understand the solidification behaviour of the WAAM
sample impact of specific parameters. The layer from top to
bottom has a significant difference as the heat input is rela-
tively calm, reducing the width of the a-phase and vice versa.
Some researchers are trying to use CMT as it is beneficial to
reduce the heat input. The pore size of CMT is much smaller
than the MIG pulse technique, which is dominant with me-
dium and large pores. Access to super-duplex stainless steel
wire that is rarely used in the WAAM process is an alternative
approach to understanding the effect of heat input. The types
of arc welding used also has a significant effect on the change
in microstructure. Thus, the correlation between the process
parameter, the composition of the wire material, thermo-
mechanical response and the phase transformation is
necessary to find the most appropriate parameters for an
acceptable microstructure.

6.3. Mechanical properties

The mechanical properties of the WAAM process tend to be

significantly influenced by the grain orientation and heat
input. Some studies relate the result of heat input to me-
chanical properties. Mainly, the studies focused on the
hardness and tensile strength of WAAM-manufactured
structures. Lervåg et al. [42] Li et al. [41] and Wang et al.
[55] have found that higher heat inputs reduce mechanical
properties when manufactured using a CMT based WAAM
Fig. 11 e Microstructure diagram [49].
process. This higher heat input resulting in incomplete
dissolution in a robust solution process due to the grain size
of deposits increasing and the increasing volume of
growth rate of the grain. The grain size increase as the wire
precipitated [45]. Lervåg et al. [42] produce super duplex
feed speed increases, heat input increases, and travel speed
stainless steel and observe Cr nitrides and secondary
constant due to solidification rate decrease. In contrast, travel
austenite when heat input increases. However, lowering
speed increase and others remain constant, resulting in faster
heat input can result in little mechanical anisotropy
solidification and slow down the grain growth rate. Besides
observed [39]. Ding et al. [53] manufactured wall structure
that, the grain structure determining the mechanical
using the GMAW-based WAAM process indicated that the

Fig. 12 e The direction of grain growth and heat conduction [45].

 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5 2141

Fig. 13 e Grain size variation observed in the inner layer region and interlayer region [48].

effect of heat input on the additive component’s mechani- effectively decreasing the energy accumulation of melting
cal properties is insignificant. However, mechanical prop- layer during the deposition process. Overall, the result
erties improve after posteweld heat treatment due to showed that the effect on mechanical properties is not
refining grain size. Su et al. [48] observed the heat input primarily due to heat input. Still, the optimum value of heat
attribute to AleMg sample mechanical properties but no input can have a substantial impact on the deposited
significant change with different travel speed [52]. This components. Nonetheless, process parameters, post-heat
study’s highest mechanical properties produced by pulse- treatment, grain size and pores significantly affect me-
based WAAM process with yield strength and ultimate chanical properties and recommend more understanding of
tensile strength reach 909 MPa and 988 MPa respectively, the correlation of all these related factors.
and elongation reaches about 7.5%. The heat input reduced
by 0.75 KJ/cm step by step with increasing deposition and

Fig. 14 e Structure of grain growth, (a), (c) Grain of single wire mainly isometric and mixed with small amount of columnar
crystal, and (b),(d) Grain of double wire is all isometric crystals [40].
2142 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5

manufacturing (WAAM). Materials 2019;12. https://doi.org/

7. Conclusion 10.3390/ma12071121.
[5] Zhou YH, Zhang ZH, Wang YP, Liu G, Zhou SY, Li YL, et al.
WAAM has the potential to lead in the AM industry. Recent Selective laser melting of typical metallic materials: an
works regarding the heat aspect suggest that finding the op- effective process prediction model developed by energy
absorption and consumption analysis. Addit Manuf
timum heat input condition in the WAAM process could
2019;25:204e17. https://doi.org/10.1016/j.addma.2018.10.046.
improve WAAM fabricated parts in terms of macrostructure,
[6] Thompson SM, Bian L, Shamsaei N, Yadollahi A. An overview
microstructure, and mechanical properties. It was argued that of Direct Laser Deposition for additive manufacturing; Part I:
the reduction of heat input should be considered to maintain transport phenomena, modeling and diagnostics. Addit
the geometrical accuracy and enhance the deposition rate in Manuf 2015;8:36e62. https://doi.org/10.1016/j.addma.
improving the macrostructure of fabricated parts. As the heat 2015.07.001.
input is lowered, the molten pool cannot spread before so- [7] Ding D, Pan Z, Cuiuri D, Li H. Wire-feed additive
manufacturing of metal components: technologies,
lidification; thus, the ratio of width to height tends to be
developments and future interests. Int J Adv Manuf Technol
smaller. Heat input also brings excellent deals with the 2015;81:465e81. https://doi.org/10.1007/s00170-015-7077-3.
microstructure on WAAM samples, affecting the grains [8] Han Q, Li Y, Zhang G. Transactions on Intelligent Welding
structure, size and pore area percentage. Some of the re- Manufacturing 2018;I:85e93. https://doi.org/10.1007/978-981-
searchers suggested controlling the process parameters that 10-5355-9.
influence on the grain such as wire feed speed, travel speed [9] Kumar M, Sharma A, Mohanty UK, Kumar SS. Additive
and heat input. Further understanding of the solidification manufacturing with welding. 2019. https://doi.org/10.1201/
9781351234825-5.
behaviour of WAAM may identify the optimum parameters
[10] Unocic RR, DuPont JN. Process efficiency measurements in
for different layer’s position. In improving the mechanical the laser engineered net shaping process. Metall Mater Trans
properties of WAAM samples, the optimum heat input along B Process Metall Mater Process Sci 2004;35:143e52. https://
with the correlation between the composition of material and doi.org/10.1007/s11663-004-0104-7.
process parameters should be further investigated so that [11] Rannar LE, Glad A, Gustafson CG. Efficient cooling with tool
better dimensional accuracy and surface quality of WAAM inserts manufactured by electron beam melting. Rapid
Prototyp J 2007;13:128e35. https://doi.org/10.1108/13552
parts.
540710750870.
[12] Santos EC, Shiomi M, Osakada K, Laoui T. Rapid
manufacturing of metal components by laser forming. Int J
Declaration of Competing Interest Mach Tool Manufact 2006;46:1459e68. https://doi.org/
10.1016/j.ijmachtools.2005.09.005.
The authors declare that they have no known competing [13] Wanjara P, Brochu M, Jahazi M. Electron beam freeforming of
financial interests or personal relationships that could have stainless steel using solid wire feed. Mater Des
2007;28:2278e86. https://doi.org/10.1016/j.
appeared to influence the work reported in this paper.
matdes.2006.08.008.
[14] Marenych OO, Ding D, Pan Z, Kostryzhev AG, Li H, Van
Duin S. Effect of chemical composition on microstructure,
Acknowledgement strength and wear resistance of wire deposited Ni-Cu alloys.
Addit Manuf 2018;24:30e6. https://doi.org/10.1016/j.add
ma.2018.08.003.
The authors acknowledge the financial support from Ministry [15] Prado-Cerqueira JL, Die
guez JL, Camacho AM. Preliminary
of Higher Education Malaysia for Fundamental Research Grant development of a wire and arc additive manufacturing
Scheme (FRGS) (FRGS/1/2020/FKM-CARE/F00437) and other system (WAAM). Procedia Manuf 2017;13:895e902. https://
support from Universiti Teknikal Malaysia Melaka (UTeM). doi.org/10.1016/j.promfg.2017.09.154.
[16] Brandl E, Baufeld B, Leyens C, Gault R. Additive
manufactured Ti-6A1-4V using welding wire: comparison of
references laser and arc beam deposition and evaluation with respect to
aerospace material specifications. Phys Procedia
2010;5:595e606. https://doi.org/10.1016/j.phpro.2010.08.087.
[17] Gu J, Cong B, Ding J, Williams SW, Zhai Y. Wireþarc additive
[1] Attaran M. The rise of 3-D printing: the advantages of
manufacturing of aluminium. In: Proc. 25th Annu. Int. Solid
additive manufacturing over traditional manufacturing. Bus
Free. Fabr. Symp. Austin, TX, USA; 2014. p. 451e8.
Horiz 2017;60:677e88. https://doi.org/10.1016/
[18] Wang H, Kovacevic R. Rapid prototyping based on variable
j.bushor.2017.05.011.
polarity gas tungsten arc welding for a 5356 aluminium alloy.
[2] Müller J, Grabowski M, Müller C, Hensel J, Unglaub J, Thiele K,
Proc Inst Mech Eng Part B J Eng Manuf 2001;215:1519e27.
et al. Design and parameter identification of wire and arc
https://doi.org/10.1243/0954405011519420.
additively manufactured (WAAM) steel bars for use in
[19] Rosli NA, Alkahari MR, Ramli FR, Maidin S, Sudin MN,
construction. Metals 2019;9. https://doi.org/10.3390/
Subramoniam S, et al. Design and development of a low-cost
met9070725.
3d metal printer. J Mech Eng Res Dev 2018;41:47e54. https://
[3] Huang R, Riddle M, Graziano D, Warren J, Das S, Nimbalkar S,
doi.org/10.26480/jmerd.03.2018.47.54.
et al. Energy and emissions saving potential of additive
[20] Lee SH. Optimization of cold metal transfer-based wire arc
manufacturing: the case of lightweight aircraft components.
additive manufacturing processes using Gaussian process
J Clean Prod 2016;135:1559e70. https://doi.org/10.1016/
regression. Metals 2020;10. https://doi.org/10.3390/
j.clepro.2015.04.109.
met10040461.
[4] Rodrigues TA, Duarte V, Miranda RM, Santos TG, Oliveira JP.
Current status and perspectives on wire and arc additive
 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5 2143

[21] Tabernero I, Paskual A, Alvarez
rez A. Study on arc
P, Sua CMT technology. Procedia Manuf 2017;13:840e7. https://
welding processes for high deposition rate additive doi.org/10.1016/j.promfg.2017.09.189.
manufacturing. Procedia CIRP, vol. 68. Elsevier B.V.; 2018. [37] Klein T, Schnall M. Control of macro-/microstructure and
p. 358e62. https://doi.org/10.1016/j.procir.2017.12.095. mechanical properties of a wire-arc additive manufactured
[22] Wu B, Ding D, Pan Z, Cuiuri D, Li H, Han J, et al. Effects of heat aluminum alloy. Int J Adv Manuf Technol 2020;108:235e44.
accumulation on the arc characteristics and metal transfer https://doi.org/10.1007/s00170-020-05396-6.
behavior in Wire Arc Additive Manufacturing of Ti6Al4V. J [38] Lin JJ, Lv YH, Liu YX, Xu BS, Sun Z, Li ZG, et al.
Mater Process Technol 2017;250:304e12. https://doi.org/ Microstructural evolution and mechanical properties of Ti-
10.1016/j.jmatprot ec.2017.07.037. 6Al-4V wall deposited by pulsed plasma arc additive
[23] Dinovitzer M, Chen X, Laliberte J, Huang X, Frei H. Effect of manufacturing. Mater Des 2016;102:30e40. https://doi.org/
wire and arc additive manufacturing (WAAM) process 10.1016/j.matdes. 2016.04. 018.
parameters on bead geometry and microstructure. Addit [39] Wang S, Gu H, Wang W, Li C, Ren L, Wang Z, et al. The
Manuf 2019;26:138e46. https://doi.org/10.1016/j.addma. influence of heat input on the microstructure and properties
2018.12.013. of wire-arc-additive-manufactured Al-Cu-Sn alloy deposits.
[24] Li JLZ, Alkahari MR, Rosli NAB, Hasan R, Sudin MN, Ramli FR. Metals 2020;10. https://doi.org/10.3390/met10010079.
Review of wire arc additive manufacturing for 3d metal [40] Wang S, Gu H, Wang W, Li C, Ren L, Wang Z, et al. Study on
printing. Int J Autom Technol 2019;13:346e53. https://doi.org/ microstructural and mechanical properties of an Al-Cu-Sn
10.20965/ijat.2019.p0346. alloy wall deposited by double-wire arc additive
[25] Pan Z, Ding D, Wu B, Cuiuri D, Li H, Norrish J. Arc welding manufacturing process. Materials 2020;13. https://doi.org/
processes for additive manufacturing: a review, vols. 3e24; 10.3390/ma13010073.
2018. https://doi.org/10.1007/978-981-10-5355-9_1. [41] Li C, Gu H, Wang W, Wang S, Ren L, Wang Z, et al. Effect of
[26] Liu J, Xu Y, Ge Y, Hou Z, Chen S. Wire and arc additive heat input on formability, microstructure, and properties of
manufacturing of metal components: a review of recent Al-7Si-0.6Mg alloys deposited by CMT-WAAM process. Appl
research developments. Int J Adv Manuf Technol Sci 2020;10. https://doi.org/10.3390/app10010070.
2020;111:149e98. https://doi.org/10.1007/s00170-020-05966-8. [42] Lervåg M, Sørensen C, Robertstad A, Brønstad BM, Nyhus B,
[27] Ali Y, Henckell P, Hildebrand J, Reimann J, Bergmann JP, Eriksson M, et al. Additive manufacturing with superduplex
Barnikol-Oettler S. Wire arc additive manufacturing of hot stainless steel wire by cmt process. Metals 2020;10. https://
work tool steel with CMT process. J Mater Process Technol doi.org/10.3390/met10020272.
2019;269:109e16. https://doi.org/10.1016/j.jmatprotec.2019. [43] Derekar KS, Addison A, Joshi SS, Zhang X, Lawrence J, Xu L,
01.034. et al. Effect of pulsed metal inert gas (pulsed-MIG) and cold
[28] Greebmalai J, Warinsiriruk E, Wang Y-T. Robot-assisted metal transfer (CMT) techniques on hydrogen dissolution in
double pulse gas metal arc welding for wire arc additive wire arc additive manufacturing (WAAM) of aluminium. Int J
manufacturing. Robot Mechatronics 2020:76e8. https:// Adv Manuf Technol 2020;107:311e31. https://doi.org/10.1007/
doi.org/10.1109/isrcs.2010.5603174. s00170-020-04946-2.
[29] Yuan L, Pan Z, Ding D, Yu Z, Van Duin S, Li H, et al. [44] Fang X, Zhang L, Chen G, Dang X, Huang K, Wang L, et al.
Fabrication of metallic parts with overhanging structures Correlations between microstructure characteristics and
using the robotic wire arc additive manufacturing. J Manuf mechanical properties in 5183 aluminium alloy fabricated by
Process 2020. https://doi.org/10.1016/j.jmapro.2020.03.018. In wire-arc additive manufacturing with different arc modes.
press. Materials 2018;11. https://doi.org/10.3390/ma11112075.
[30] Wu B, Pan Z, Ding D, Cuiuri D, Li H. Effects of heat [45] Cheepu M, Lee CI, Cho SM. Microstructural characteristics of
accumulation on microstructure and mechanical properties wire arc additive manufacturing with inconel 625 by super-
of Ti6Al4V alloy deposited by wire arc additive TIG welding. Trans Indian Inst Met 2020;73:1475e9. https://
manufacturing. Addit Manuf 2018;23:151e60. https://doi.org/ doi.org/10.1007/s12666-020-01915-x.
10.1016/j. addma.2018.08. 004. [46] Lu T, Liu C, Li Z, Wu Q, Wang J, Xu T, et al. Hot-wire arc
[31] Chen W, Chen Y, Zhang T, Wen T, Yin Z, Feng X. Effect of additive manufacturing Tie6.5Ale2Zre1Moe1V titanium
ultrasonic vibration and interpass temperature on alloy: pore characterization, microstructural evolution, and
microstructure and mechanical properties of Cu-8Al-2Ni- mechanical properties. J Alloys Compd 2020:817. https://
2Fe-2Mn alloy fabricated by wire arc additive manufacturing. doi.org/10.1016/j.jallcom.2019.153334.
Metals 2020;10. https://doi.org/10.3390/met10020215. [47] Hosseini VA, Ho € gstro
€ m M, Hurtig K, Asuncion M, Bermejo V,
[32] Ji L, Lu J, Liu C, Jing C, Fan H, Ma S. Microstructure and Stridh L, et al. Wire-arc additive manufacturing of a duplex
mechanical properties of 304L steel fabricated by arc additive stainless steel: thermal cycle analysis and microstructure
manufacturing. MATEC Web Conf 2017;128. https://doi.org/ characterization. Weld World 2019;63:975e87. https://
10.1051/matecconf/201712803006. doi.org/10.1007/s40194-019-00735-y.
[33] Moher D, Shamseer L, Clarke M, Ghersi D, Liberati A, [48] Su C, Chen X, Gao C, Wang Y. Effect of heat input on
Petticrew M, et al. Preferred reporting items for systematic microstructure and mechanical properties of Al-Mg alloys
review and meta-analysis protocols (PRISMA-P) 2015 fabricated by WAAM. Appl Surf Sci 2019;486:431e40. https://
statement. Rev Espan ~ ola Nutr Humana Diete
tica doi.org/10.1016/j.apsusc.2019.04.255.
2016;20:148e60. https://doi.org/10.1186/2046-4053-4-1. [49] Li Z, Liu C, Xu T, Ji L, Wang D, Lu J, et al. Reducing arc heat
[34] Mohamad F, Teh J. Impacts of energy storage system on input and obtaining equiaxed grains by hot-wire method
power system reliability: a systematic review. Energies during arc additive manufacturing titanium alloy. Mater Sci
2018;11. https://doi.org/10.3390/en110 71749. Eng, A 2019;742:287e94. https://doi.org/10.1016/j.msea.2018.
[35] Pickin CG, Williams SW, Lunt M. Characterisation of the cold 11.022.
metal transfer (CMT) process and its application for low [50] Gu J, Bai J, Ding J, Williams S, Wang L, Liu K. Design and
dilution cladding. J Mater Process Technol 2011;211:496e502. cracking susceptibility of additively manufactured Al-Cu-Mg
https://doi.org/10.1016/j.jmatprotec.2010.11.005. alloys with tandem wires and pulsed arc. J Mater Process
[36] Gonza
lez J, Rodrı́guez I, Prado-Cerqueira JL, Die
guez JL, Technol 2018;262:210e20. https://doi.org/10.1016/
Pereira A. Additive manufacturing with GMAW welding and j.jmatprotec .2018.06.030.
2144 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5

[51] Ayarkwa KF, Williams SW, Ding J. Assessing the effect of TIG [65] Gierth M, Henckell P, Ali Y, Scholl J, Bergmann JP. wire arc
alternating current time cycle on aluminium wire þ arc additive manufacturing (WAAM) of aluminum alloy
additive manufacture. Addit Manuf 2017;18:186e93. https:// AlMg5Mn with energy-reduced gas metal arc welding
doi.org/10.1016/j.addma.2017.10.005. (GMAW). Int J Adv Manuf Technol 2020;13:2671. https://
[52] Li F, Chen S, Shi J, Zhao Y, Tian H. Thermoelectric cooling- doi.org/10.3390/ma13 122671.
aided bead geometry regulation in wire and arc-based [66] Yang X, Liu J, Wang Z, Lin X, Liu F, Huang W, et al. Materials
additive manufacturing of thin-walled structures. Appl Sci Science & Engineering A Microstructure and mechanical
2018;8. https://doi.org/10.3390/app8020207. properties of wire and arc additive manufactured AZ31
[53] Ding D, Pan Z, van Duin S, Li H, Shen C. Fabricating superior magnesium alloy using cold metal transfer process. Mater
NiAl bronze components through wire arc additive Sci Eng, A 2020;774:138942. https://doi.org/10.1016/
manufacturing. Materials 2016;9. https://doi.org/10.3390/ j.msea.2020.138942.
ma9080652. [67] Guo M, Jia C, Zhou J, Liu W, Wu C. Investigating the
[54] Xiong J, Zhang G, Zhang W. Forming appearance analysis in generation process of molten droplets and arc plasma in the
multi-layer single-pass GMAW-based additive confined space during compulsively constricted WAAM. J
manufacturing. Int J Adv Manuf Technol 2015;80:1767e76. Mater Process Technol 2020;275. https://doi.org/10.1016/
https://doi.org/10.1007/s00170-015-7112-4. j.jmatprotec.2019.116355.
[55] Wang P, Zhang H, Zhu H, Li Q, Feng M. Wire-arc additive [68] Wu W, Xue J, Zhang Z, Yao P. Comparative study of 316L
manufacturing of AZ31 magnesium alloy fabricated by cold depositions by two welding current processes. 0 Mater
metal transfer heat source: processing , microstructure , and Manuf Process 2019:1e7. https://doi.org/10.1080/
mechanical behavior. J Mater Process Technol 10426914.2019.1643473.
2021;288:116895. https://doi.org/10.1016/ [69] Zhang Y, Gao M, Zeng X. Effect of process parameters on
j.jmatprotec.2020.116895. mechanical properties of wire and arc additive-
[56] Wang C, Suder W, Ding J, Williams S. The e ff ect of wire size manufactured AlCu6Mn. JOM 2019;71:886e92. https://
on high deposition rate wire and plasma arc additive doi.org/10.1007/s11837-018-3210-8.
manufacture of Ti-6Al-4V. J Mater Process Technol [70] Youheng F, Guilan W, Haiou Z, Liye L. Optimization of
2021;288:116842. https://doi.org/10.1016/ surface appearance for wire and arc additive manufacturing
j.jmatprotec.2020.116842. of Bainite steel. Int J Adv Manuf Technol 2017;91:301e13.
[57] Aldalur E, Veiga F, Sua
rez A, Bilbao J, Lamikiz A. High https://doi.org/10.1007/s00170-016-9621-1.
deposition wire arc additive manufacturing of mild steel: [71] Henckell P, Gierth M, Ali Y, Reimann J, Bergmann JP.
strategies and heat input effect on microstructure and Reduction of energy input in wire arc additive
mechanical properties. J Manuf Process 2020;58:615e26. manufacturing (WAAM) with gas metal arc welding. GMAW)
https://doi.org/10.1016/j.jmapro.2020.08.060. Materials 2020;13:2491. https://doi.org/10.3390/ma13112491.
[58] Medeiros R, Roy MJ, Morana R, Prangnell PB. Process [72] Wang B, Yang G, Zhou S, Cui C, Qin L. Effects of on-line
response of Inconel 718 to wire þ arc additive manufacturing vortex cooling on the microstructure and mechanical
with cold metal transfer. Mater Des 2020;195:109031. https:// properties of wire arc additively manufactured Al-Mg alloy.
doi.org/10.1016/j.matdes.2020.109031. Metals 2020;10:1004. https://doi.org/10.3390/met10 081004.
[59] Panchenko O, Kurushkin D, Mushnikov I, Khismatullin A, [73] Artaza T, Bhujangrao T, Suarez A, Veiga F, Lamikiz A.
Popovich A. A high-performance WAAM process for Al e Mg Influence of heat input on the formation of laves phases and
e Mn using controlled short-circuiting metal transfer at hot cracking in plasma arc welding (PAW) additive
increased wire feed rate and increased travel speed. Mater manufacturing of inconel 718. Metals (Basel) 2020;10:771.
Des 2020;195:109040. https://doi.org/10.1016/ https://doi.org/10.3390/met10060771.
j.matdes.2020.109040. [74] Lee SH. CMT-based wire arc additive manufacturing using
[60] Abe T, Sasahara H. Thermal sensing and heat input control 316L stainless steel: effect of heat accumulation on the
for thin-walled structure building based on numerical multi-layer deposits. Metals (Basel) 2020;10:278. https://
simulation for wire and arc additive manufacturing. Addit doi.org/10.3390/met10020278.
Manuf 2020;35:101357. https://doi.org/10.1016/j.addma. [75] Chen M, Zhang D, Wu C. Current waveform effects on CMT
2020.101357. welding of mild steel. J Mater Process Technol
[61] Liu G, Xiong J. External filler wire based GMA-AM process of 2017;243:395e404. https://doi.org/10.1016/j.jmat protec.2017.
2219 aluminum alloy. 00 Mater Manuf Process 2020:1e10. 01.004.
https://doi.org/10.1080/10426914.2020.1779936.
[62] Reisgen U, Sharma R, Mann S, Oster L. Increasing the Associate Professor Ir. Ts. Dr. Mohd Rizal Alkahari is a Deputy Di-
manufacturing efficiency of WAAM by advanced cooling rector at Center for Strategy, Quality and Risk Management and an
strategies. Weld World 2020;64:1409e16. https://doi.org/ Associate Professor at Faculty of Mechanical Engineering, Universiti
10.1007/s40194-020-00930-2. Teknikal Malaysia Melaka (UTeM), Malaysia. He received his B.Eng
[63] Spaniol E, Ungethüm T, Trautmann M, Andrusch K, Hertel M, (Hons) from International Islamic University Malaysia (IIUM). He
Füssel U. Development of a novel TIG hot-wire process for was a practising manufacturing engineer in industry for few years
wire and arc additive manufacturing. Weld World before joining the university as an academic staff. He completed his
2020;64:1329e40. https://doi.org/10.1007/s40194-020-00871- MSc in Manufacturing System Engineering (with Distinction) from
w. the University of Warwick, United Kingdom. He received his Ph.D for
[64] Yildiz AS, Davut K, Koc B, Yilmaz O. Wire arc additive the research in the area of 3D printing/additive manufacturing (AM)
manufacturing of high-strength low alloy steels: study of from Kanazawa University, Japan. His main research interest is on
process parameters and their influence on the bead 3D printing/additive manufacturing (AM) particularly related to se-
geometry and mechanical characteristics. Int J Adv Manuf lective laser sintering/selective laser melting (SLS/SLM), fused
Technol 2020;108:3391e404. https://doi.org/10.1007/s00170- deposition modeling (FDM) and wire arc additive manufacturing
020-05482-9. (WAAM). Other relevant areas that interest him are Quality
 j o u r n a l o f m a t e r i a l s r e s e a r c h a n d t e c h n o l o g y 2 0 2 1 ; 1 1 : 2 1 2 7 e2 1 4 5 2145

Management, Product Design and Development and Manufacturing Other than that, he is a member of the Institution of Engineers
Processes. He is also a certified Professional Engineer with Practising Malaysia (IEM), Malaysia Society for Engineering and Technology
Certificate registered with Board of Engineer Malaysia (BEM), Pro- (MySET), Japan Society of Mechanical Engineers (JSME), Japan Soci-
fessional Technologist as recognized by Malaysia Board of Tech- ety of Precision Engineering (JSPE), Malaysian Board of Technologists
nologists (MBOT) and Global Certified Lead Auditor for ISO9001:2015. (MBOT) and International Association of Engineers (IAENG).