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<p>Wire-Arc Directed Energy Deposition (Wire-Arc DED), an emerging additive manufacturing (AM) technology, has gained increasing attention in fabricating medium-to-large scale components due to its cost-effectiveness and high deposition efficiency. Among various types of stainless steels, austenitic stainless steel stands out for its superior mechanical properties and exceptional corrosion resistance. Therefore, Wire-Arc DED of austenitic stainless steel has become a prominent research focus. This review systematically summarizes the microstructure and properties, defect issues, novel techniques for enhancing properties of Wire-Arc DED austenitic stainless steel. The configurations, operational characteristics, and application fields of mainstream heat source systems of Wire-Arc DED are analyzed. The anisotropic mechanical behavior and microstructural inhomogeneity of austenitic stainless steel produced by Wire-Arc DED are concisely overviewed, with emphasis on the influence of process parameters including wire feed speed and angle, travel speed, power polarity, and arc types. The mechanism and influencing factors of defects such as residual stress (RS) accumulation, distortion, porosity and cracking are elucidated alongside their suppressing strategies. Some advanced optimization approaches, including path planning, shielding gas, pulsed-arc modulation, hot-wire feeding, interpass cooling, ultrasonic impact treatment (UIT), in-situ rolling, and post-deposition heat treatment, are demonstrated to significantly enhance properties of Wire-Arc DED austenitic stainless steel in view of metallurgical reaction and process. Furthermore, the corrosion resistance and fatigue behavior of as-built components under service conditions are also discussed and should attract more attention. The future direction of developing Wire-Arc DED austenitic stainless steel can focus on the interdisciplinary nature of Wire-Arc DED development, integrating materials science, thermomechanical engineering and digital process monitoring, in order to promote the popularization of Wire-Arc DED.</p>

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A comprehensive review on the Wire-Arc DED austenitic stainless steel: advanced technologies, microstructure, defect issues, enhancing properties

  • 期刊论文

  • 发表日期：

    2026年1月22日

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  • Yuxuan Ren,
  • Kun Liu,
  • Changjun Huang,
  • Bingbing Chen,
  • Shaoning Geng,
  • Jie Li,
  • Guoxiang Xu

摘要

Wire-Arc Directed Energy Deposition (Wire-Arc DED), an emerging additive manufacturing (AM) technology, has gained increasing attention in fabricating medium-to-large scale components due to its cost-effectiveness and high deposition efficiency. Among various types of stainless steels, austenitic stainless steel stands out for its superior mechanical properties and exceptional corrosion resistance. Therefore, Wire-Arc DED of austenitic stainless steel has become a prominent research focus. This review systematically summarizes the microstructure and properties, defect issues, novel techniques for enhancing properties of Wire-Arc DED austenitic stainless steel. The configurations, operational characteristics, and application fields of mainstream heat source systems of Wire-Arc DED are analyzed. The anisotropic mechanical behavior and microstructural inhomogeneity of austenitic stainless steel produced by Wire-Arc DED are concisely overviewed, with emphasis on the influence of process parameters including wire feed speed and angle, travel speed, power polarity, and arc types. The mechanism and influencing factors of defects such as residual stress (RS) accumulation, distortion, porosity and cracking are elucidated alongside their suppressing strategies. Some advanced optimization approaches, including path planning, shielding gas, pulsed-arc modulation, hot-wire feeding, interpass cooling, ultrasonic impact treatment (UIT), in-situ rolling, and post-deposition heat treatment, are demonstrated to significantly enhance properties of Wire-Arc DED austenitic stainless steel in view of metallurgical reaction and process. Furthermore, the corrosion resistance and fatigue behavior of as-built components under service conditions are also discussed and should attract more attention. The future direction of developing Wire-Arc DED austenitic stainless steel can focus on the interdisciplinary nature of Wire-Arc DED development, integrating materials science, thermomechanical engineering and digital process monitoring, in order to promote the popularization of Wire-Arc DED.