Wire-feed additive manufacturing of metal components: technologies, developments and future interests

  • Donghong DingEmail author
  • Zengxi Pan
  • Dominic Cuiuri
  • Huijun Li


Wire-feed additive manufacturing (AM) is a promising alternative to traditional subtractive manufacturing for fabricating large expensive metal components with complex geometry. The current research focus on wire-feed AM is trying to produce complex-shaped functional metal components with good geometry accuracy, surface finish and material property to meet the demanding requirements from aerospace, automotive and rapid tooling industry. Wire-feed AM processes generally involve high residual stresses and distortions due to the excessive heat input and high deposition rate. The influences of process conditions, such as energy input, wire-feed rate, welding speed, deposition pattern and deposition sequences, etc., on thermal history and resultant residual stresses of AM-processed components needs to be further understood. In addition, poor accuracy and surface finish of the process limit the applications of wire-feed AM technology. In this paper, after an introduction of various wire-feed AM technologies and its characteristics, an in depth review of various process aspects of wire-feed AM, including quality and accuracy of wire-feed AM processed components, will be presented. The overall objective is to identify the current challenges for wire-feed AM as well as point out the future research direction.


Additive manufacturing Wire Metal component Review 


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Copyright information

© Springer-Verlag London 2015

Authors and Affiliations

  • Donghong Ding
    • 1
    Email author
  • Zengxi Pan
    • 1
  • Dominic Cuiuri
    • 1
  • Huijun Li
    • 1
  1. 1.School of Mechanical, Materials, and Mechatronics Engineering, Faculty of Engineering and Information SciencesUniversity of WollongongWollongongAustralia

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