Selection and Optimization of Process Parameters in Wire Arc Additive Manufacturing for Automotive Structural Applications

Wire Arc Additive Manufacturing (WAAM) has emerged as a promising technology for fabricating large, complex metal structures with reduced material wastage and improved design flexibility. In the automotive sector, WAAM offers significant potential for producing lightweight and high-strength components, particularly for structural applications. However, the quality and performance of WAAM-fabricated parts are highly dependent on the careful selection and optimization of process parameters such as wire feed rate, travel speed, arc voltage, current, and inter-pass temperature. This review focuses on the systematic evaluation of key process parameters influencing the mechanical properties, surface integrity, dimensional accuracy, and microstructural characteristics of WAAM-produced structures intended for automotive applications. The study also explores various optimization techniques—such as Taguchi, response surface methodology (RSM), and artificial intelligence (AI)-based approaches—that have been employed to achieve desired part quality and process efficiency. Finally, the paper highlights current challenges and future prospects for the integration of WAAM in mainstream automotive manufacturing.