Research progress and challenges in forming control of wire arc additive manufacturing

Wire arc additive manufacturing (WAAM), with its high deposition rate, strong openness, high flexibility, and low cost, is gradually emerging as a promising method for manufacturing large and complex metallic structural parts in the aerospace field. The forming detection and control of molten pools and weld beads are crucial for achieving forming and performance control of the WAAM process. Forming quality control is gradually realized through the optimization of welding process parameters, precise regulation of the additive forming process, and effective management of heat sources and droplet transfer. Key research directions in forming control include combining intelligent algorithms and forming strategies to regulate weld bead shapes and lap process parameters, developing intelligent process parameter regulation systems, and introducing external forced regulation means to improve the performance of welding heat sources and precisely control droplet transfer. The research progress of WAAM forming control methods is reviewed, the main challenges currently faced are analyzed, and the development prospects of WAAM technology are prospected.