Department
Engineering Technology
Additional Department
Mechanical Engineering Technology
Document Type
Article
Publication Date
Fall 8-21-2025
Embargo Period
8-29-2025
Abstract
Metallic multi-material structures are heterogeneous structures characterized by changing composition, microstructures, and site-specific characteristics, advantageous for numerous applications where multifunctionality is desired. Metallic multi-material structures are known as bimetallic structures (BSs), which are functionally graded materials (FGMs). In recent years, wire-arc additive manufacturing (WAAM) advanced as a promising additive manufacturing process to realize the fabrication of these structures due to its high deposition rate, cost-effectiveness, and material utilization efficiency. This review presents a comprehensive overview of the recent progress, processing strategies, and scientific challenges in WAAM of multi-material structures. The paper begins with an introduction to multi-material structures, followed by a bibliometric analysis of the current research landscape. Conventional and additive manufacturing fabrication approaches are presented. The review highlights key developments in processing strategies and critically evaluates research studies on WAAM of BS and FGMs. Major scientific challenges, including porosity, lack of fusion, residual stresses, cracking, material compatibility, and brittle intermetallic phase formation, are critically analyzed. Additionally, modeling, simulation, and process automation issues are discussed as barriers to industrial-scale implementation. The paper concludes with an outlook on future research directions to address existing challenges and accelerate the adoption of WAAM for complex multi-material components.
Journal Title
Journal of Manufacturing and Materials Processing
Journal ISSN
2504-4494
Volume
9
Issue
8
Digital Object Identifier (DOI)
10.3390/jmmp9080284