Multi-wire directed energy deposition-arc of aluminum alloys: process control, applications and challenges
1 School of Material Science and Engineering, Hebei University of Science and Technology, Shijiazhuang 050018, China
2 Hebei Key Laboratory of Material Near-Net Forming Technology, Shijiazhuang 050018, China
3 Shijiazhuang Key Laboratory of Intelligent Technology for Metallic Materials, Shijiazhuang 050018, China
  • Volume
  • Citation
    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. 
  • DOI
    10.55092/ae20260002
  • Copyright
    Copyright2026 by the authors. Published by ELSP.
Abstract

The global manufacturing industry is undergoing a transformation towards lightweight and high-performance development, and aluminum alloys have become the dominant material for key components of high-end equipment. The conventional single-wire directed energy deposition-arc (single-wire DED-arc) suffers from inherent limitations, including excessive heat input and fixed compositions of commercial welding wires. While multi-wire directed energy deposition-arc (multi-wire DED-arc) technology presents significant advantages, its development still faces numerous challenges. This paper reviews the research status and engineering progress of multi-wire DED-arc technology for aluminum alloys, analyzes the synergistic regulation mechanism of three core process dimensions (wire feeding rate regulation, current-voltage synergistic control, and inter-wire geometric parameter optimization), and summarizes its applications in the automotive, rail transit, and aerospace fields. It further identifies the core advantages and key bottlenecks of this technology, establishes a unified theoretical framework for multi-wire DED-arc aluminum alloy forming, and can provide a valuable reference for future research in this field and the development of dedicated precision equipment.

Keywords

multi-wire directed energy deposition-arc (multi-wire DED-arc); aluminum alloy; in-situ alloying; precision forming

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