A comprehensive review published in Advanced Equipment systematically sorts out the global research and engineering progress of multi-wire arc 3D printing (multi-wire DED-arc) for aluminum alloys. It constructs a complete three-dimensional collaborative process control framework for this technology, clarifies its core advantages over traditional manufacturing methods, identifies key industrialization bottlenecks, and provides a clear roadmap for future development.
Aluminum alloys have become indispensable core materials for lightweight manufacturing across aerospace, automotive and rail transit sectors, driven by global demand for energy efficiency and high-performance equipment. Their unique combination of low density, high specific strength, excellent corrosion resistance and recyclability makes them ideal for reducing component weight while maintaining structural integrity. However, existing production methods face persistent limitations that restrict their full potential. Traditional casting and forging processes require costly custom molds and lengthy production cycles, making them uneconomical for small-batch customized components. Laser-based 3D printing, while precise, is too slow and size-restricted for large-scale parts, and conventional single-wire arc printing is limited to fixed material compositions and suffers from excessive heat input that causes deformation and cracking.
Against this backdrop, researchers from Hebei University of Science and Technology have systematically reviewed global peer-reviewed studies and industrial practices in multi-wire arc 3D printing. The team organized previously fragmented research findings into a cohesive three-dimensional collaborative process control system that integrates three interrelated core dimensions. First, precise regulation of individual wire feeding speeds enables flexible on-the-fly adjustment of alloy compositions, a capability unique to multi-wire technology. Second, synergistic control of current and voltage reduces heat input, suppresses arc interference between wires, and minimizes deformation and cracking defects. Third, quantitative optimization of inter-wire geometric parameters ensures consistent forming quality and component density.
The review also summarizes remarkable engineering applications verified globally:
In automotive and rail transit, the technology achieves high deposition rates with over 90% material utilization. Hot-wire assisted variants can significantly reduce porosity in aluminum alloy parts while greatly improving manufacturing efficiency.
In aerospace, researchers have rapidly manufactured large-scale aluminum alloy wing ribs, and overcome the long-standing hot cracking problem of high-strength 7xxx series aluminum alloys.
Despite these advances, the review points out three major challenges: incomplete multi-field coupling theoretical framework, insufficient stability of core equipment components, and lagging development of special welding wires and industry standards. It further proposes four key future directions: strengthening basic theoretical research, tackling core component technologies, promoting intelligent equipment upgrading, and establishing a full-chain engineering application system.
This paper "Multi-wire directed energy deposition-arc of aluminum alloys: process control, applications and challenges" was published in Advanced Equipment.
Xu L, Liang Z, Wang D, Wang L. Multi-wire directed energy deposition-arc of aluminum alloys: process control, applications and challenges. Adv. Equip . 2026(1):0002, https://doi.org/10.55092/ae20260002.
Advanced Equipment
Literature review
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Multi-wire directed energy deposition-arc of aluminum alloys: process control, applications and challenges
29-May-2026