A Review of High-Strength Aluminum-Copper Alloys Fabricated by Wire Arc Additive Manufacturing: Microstructure, Properties, Defects, and Post-processing

Wire arc additive manufacturing (WAAM) techniques have been gaining increasing attention in the contemporary manufacturing sector due to their advantages in economically producing large-sized metallic components with relatively high deposition rates. High-strength Al-Cu alloys are widely used in aerospace, military, and automotive industries applications due to their high specific strength and excellent processability. WAAM offers an efficient way to produce large-sized high-strength Al-Cu alloy components, and the related field is rapidly evolving. This article reviews the current research for WAAM high-strength Al-Cu alloys on the manufacturing process, solidification microstructure, common defects, mechanical properties, and post-processing processes. Research findings have been positive regarding the microstructure and mechanical properties of WAAM high-strength Al-Cu alloys. Finally, this article outlines the development prospects of WAAM high-strength Al-Cu alloys based on the previous research.