Gas metal arc welding based additive manufacturing—a review

• Published in: CIRP journal of manufacturing science and technology Vol. 33; pp. 398 - 442
• Main Authors: Pattanayak, Suvranshu, Sahoo, Susanta Kumar
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.05.2021
• Subjects: GMAW-AM; Key parameters; Modelling approaches; Parameter combinations and range; Percentage contributions; Strategies adopted; Wire electrode materials; Parameter combinations and range; Strategies adopted; GMAW-AM; Wire electrode materials; Percentage contributions; Key parameters; Modelling approaches
• ISSN: 1755-5817; 1878-0016
• DOI: 10.1016/j.cirpj.2021.04.010

Additive manufacturing (AM) route is a promising approach for fabricating complex and lightweight metallic structures that have applications in various sectors such as automotive, aerospace, and biomedical industries. Laser, electron beam, and electric arc are the common power sources available for AM. Out of different metal AM techniques, wire-feed additive manufacturing has been considered as a promising alternative for fabricating metallic parts for various applications. As it provides a high deposition rate, material utilization, density, and low cost with a low risk of contamination and porosity compared to powder-based raw material. Gas metal arc welding-based additive manufacturing (GMAW-AM) is a specific approach based on wire-feed AM. This technology uses a low-cost equipment which is suitable for fabricating components with large geometries and moderate structural complexity. These advantages attract the researchers and production industries for further developments in GMAW-AM to enhance its deposition performance, process capability, and applicability in various fields. The quality of metal deposited in GMAW-AM is generally represented by the surface form, dimensional quality, mechanical properties, relative density, hardness, etc. The present paper encompasses the research developments that occurred in the field of GMAW-AM in recent years. This review begins with the GMAW-AM procedure, performance capability, identification of factors affecting the deposition performance, and strategies adopted to overcome these issues. Several aspects such as mathematical modelling, optimization, key process parameters, and their combinations for a wide range of wire electrode material and percentage contributions are also reviewed and depicted in detail. Also, a comprehensive conclusion of this review, along with future perspectives, is explored subsequently. The current review work will help future researchers to select different wire materials and GMAW-AM parameters to achieve better performances. Lastly, several future research directions are suggested, specifically the need of a framework for GMAW-AM processes for fabricating quality products with minimum distortion.