A review of wire-arc additive manufacturing magnesium alloys: parameters, microstructure, properties and strengthening strategies

With lightweighting emerging as a critical technological trajectory in aerospace and next-generation transport, the fabrication of large, complex magnesium alloy components is increasingly urgent. Due to its high deposition rate and scalability, wire-arc additive manufacturing (WAAM) offers a promising paradigm for the near-net-shape forming of these materials. This paper systematically reviews the current research status of WAAM magnesium alloys. First, it analyzes the unique challenges faced by the application of the WAAM process to magnesium alloys; then, it summarizes the intrinsic relationship between process, microstructure, and properties from the aspects of process parameter control, microstructure evolution, mechanical properties, and corrosion behavior. Furthermore, we synthesize emerging in situ hybrid manufacturing strategies-utilizing external field assistance and inter-layer mechanical treatments-that achieve integrated control over both component geometry and material properties. Finally, we delineate critical frontiers for future investigation, including tailored alloy design, intelligent process control, and rigorous performance evaluation, to accelerate the deployment of high-performance magnesium WAAM technologies.