A comprehensive review and future perspectives of simulation approaches in wire arc additive manufacturing (WAAM)

Wire arc additive manufacturing (WAAM) has emerged as a promising technique for producing large-scale metal components, favoured by high deposition rates, flexibility and low cost. Despite its potential, the complexity of WAAM processes, which involves intricate thermal dynamics, phase transitions,...

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Main Authors: Zhonghao Chen, Lei Yuan, Zengxi Pan, Hongtao Zhu, Ninshu Ma, Donghong Ding, Huijun Li
Format: Article
Language:English
Published: IOP Publishing 2025-01-01
Series:International Journal of Extreme Manufacturing
Subjects:
Online Access:https://doi.org/10.1088/2631-7990/ada099
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author Zhonghao Chen
Lei Yuan
Zengxi Pan
Hongtao Zhu
Ninshu Ma
Donghong Ding
Huijun Li
author_facet Zhonghao Chen
Lei Yuan
Zengxi Pan
Hongtao Zhu
Ninshu Ma
Donghong Ding
Huijun Li
author_sort Zhonghao Chen
collection DOAJ
description Wire arc additive manufacturing (WAAM) has emerged as a promising technique for producing large-scale metal components, favoured by high deposition rates, flexibility and low cost. Despite its potential, the complexity of WAAM processes, which involves intricate thermal dynamics, phase transitions, and metallurgical, mechanical, and chemical interactions, presents considerable challenges in final product qualities. Simulation technologies in WAAM have proven invaluable, providing accurate predictions in key areas such as material properties, defect identification, deposit morphology, and residual stress. These predictions play a critical role in optimising manufacturing strategies for the final product. This paper provides a comprehensive review of the simulation techniques applied in WAAM, tracing developments from 2013 to 2023. Initially, it analyses the current challenges faced by simulation methods in three main areas. Subsequently, the review explores the current modelling approaches and the applications of these simulations. Following this, the paper discusses the present state of WAAM simulation, identifying specific issues inherent to WAAM simulation itself. Finally, through a thorough review of existing literature and related analysis, the paper offers future perspectives on potential advancements in WAAM simulation strategies.
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publishDate 2025-01-01
publisher IOP Publishing
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series International Journal of Extreme Manufacturing
spelling doaj-art-5f77874095c44be295df5752b2d6eec42025-01-13T06:49:17ZengIOP PublishingInternational Journal of Extreme Manufacturing2631-79902025-01-017202201610.1088/2631-7990/ada099A comprehensive review and future perspectives of simulation approaches in wire arc additive manufacturing (WAAM)Zhonghao Chen0Lei Yuan1https://orcid.org/0000-0002-0532-7745Zengxi Pan2Hongtao Zhu3https://orcid.org/0000-0003-1405-7828Ninshu Ma4Donghong Ding5Huijun Li6School of Mechanical and Power Engineering, Nanjing Tech University , Nanjing 211816, People’s Republic of China; Institute of Reliability Centered Manufacturing, Nanjing Tech University , Nanjing 211816, People’s Republic of China; School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong , Wollongong, New South Wales 2522, AustraliaSchool of Mechanical and Power Engineering, Nanjing Tech University , Nanjing 211816, People’s Republic of China; Institute of Reliability Centered Manufacturing, Nanjing Tech University , Nanjing 211816, People’s Republic of China; School of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong , Wollongong, New South Wales 2522, AustraliaSchool of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong , Wollongong, New South Wales 2522, AustraliaSchool of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong , Wollongong, New South Wales 2522, AustraliaJoining and Welding Research Institute, Osaka University , Mihogaoka 11-1, Ibaraki, Osaka 567-0047, JapanSchool of Mechanical and Power Engineering, Nanjing Tech University , Nanjing 211816, People’s Republic of China; Institute of Reliability Centered Manufacturing, Nanjing Tech University , Nanjing 211816, People’s Republic of ChinaSchool of Mechanical, Materials, Mechatronic and Biomedical Engineering, University of Wollongong , Wollongong, New South Wales 2522, AustraliaWire arc additive manufacturing (WAAM) has emerged as a promising technique for producing large-scale metal components, favoured by high deposition rates, flexibility and low cost. Despite its potential, the complexity of WAAM processes, which involves intricate thermal dynamics, phase transitions, and metallurgical, mechanical, and chemical interactions, presents considerable challenges in final product qualities. Simulation technologies in WAAM have proven invaluable, providing accurate predictions in key areas such as material properties, defect identification, deposit morphology, and residual stress. These predictions play a critical role in optimising manufacturing strategies for the final product. This paper provides a comprehensive review of the simulation techniques applied in WAAM, tracing developments from 2013 to 2023. Initially, it analyses the current challenges faced by simulation methods in three main areas. Subsequently, the review explores the current modelling approaches and the applications of these simulations. Following this, the paper discusses the present state of WAAM simulation, identifying specific issues inherent to WAAM simulation itself. Finally, through a thorough review of existing literature and related analysis, the paper offers future perspectives on potential advancements in WAAM simulation strategies.https://doi.org/10.1088/2631-7990/ada099wire arc additive manufacturingsimulationmachine learningcomputational fluid dynamicsfinite element method3D printing
spellingShingle Zhonghao Chen
Lei Yuan
Zengxi Pan
Hongtao Zhu
Ninshu Ma
Donghong Ding
Huijun Li
A comprehensive review and future perspectives of simulation approaches in wire arc additive manufacturing (WAAM)
International Journal of Extreme Manufacturing
wire arc additive manufacturing
simulation
machine learning
computational fluid dynamics
finite element method
3D printing
title A comprehensive review and future perspectives of simulation approaches in wire arc additive manufacturing (WAAM)
title_full A comprehensive review and future perspectives of simulation approaches in wire arc additive manufacturing (WAAM)
title_fullStr A comprehensive review and future perspectives of simulation approaches in wire arc additive manufacturing (WAAM)
title_full_unstemmed A comprehensive review and future perspectives of simulation approaches in wire arc additive manufacturing (WAAM)
title_short A comprehensive review and future perspectives of simulation approaches in wire arc additive manufacturing (WAAM)
title_sort comprehensive review and future perspectives of simulation approaches in wire arc additive manufacturing waam
topic wire arc additive manufacturing
simulation
machine learning
computational fluid dynamics
finite element method
3D printing
url https://doi.org/10.1088/2631-7990/ada099
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