Wire arc additive manufacturing (WAAM) is an emerging and promising technology for producing medium-to-large-scale metallic components/structures for different industries, i.e., aerospace, automotive, shipbuilding, etc. It is now a feasible alternative to traditional manufacturing processes due to its shorter lead time, low material waste, and cost-effectiveness. WAAM has been widely used to produce components using different materials, including copper-based alloy wires, in the past decades. This review paper highlights the critical aspects of WAAM process in terms of technology, various challenges faced during WAAM process, different in-process and post-process operations, process monitoring methods, various gases, and different types of materials used in WAAM process. Furthermore, it briefly overviews recent developments in depositing different copper-based alloys via WAAM process.

In many cases, the functional performance of additively manufactured components can only be ensured by finishing the functional surfaces. Various methods are available for this purpose. This paper presents a procedure for selecting suitable processes for finishing laser beam melting additive–manufactured parts which is ultimately based on technological knowledge. It was experimentally proven that the use of several consecutive finishing processes is beneficial to achieve better surface quality. One finishing process chain was particularly effective (namely particle blasting/vibratory grinding/plasma electrolytic polishing) and the technological limits of this method were investigated in this study. The optimal parameters for this process combination ensured a surface roughness S_a < 1 µm.

The technology of additive manufacturing (AM) has transformed the fields of machinery, aerospace, and electronics. Adopting cost-effective, precise, and rapid procedures in AM is one of the major concerns of today’s industry. Stereolithography is a promising AM technique that is thought to meet these requirements. However, the fact that materials printed with stereolithography do not have good mechanical properties limits their application, such as in biomedicine and aerospace. Previous studies have shown the shortcomings of stereolithography printers. This research focuses on enhancing the mechanical characteristics of the polymer resin used in stereolithography (SLA)-like liquid crystal display (LCD) 3D printers by fabricating a new AM composite material with carbon fibers. For this reason, chopped carbon fibers (0.1 mm size) at amounts of 0.25 wt% and 0.5 wt% have been used with Acrylonitrile butadiene styrene (ABS)-like photopolymer transparent resin during the printing process, and three different print layer thicknesses were tested. For the design of the experiment (DoE), Q-DAS software was used to analyze the resulting data. A tensile-testing machine was utilized to determine the ultimate strength using the ASTM D638 standard. The results show an increase in the ultimate strength by adding carbon fiber to some extent, but after a certain percentage of carbon fiber added, the strength drops off.

Copper-based alloys are widely known for their high thermal and electrical conductivity. Although the use of these alloys in powder-based additive manufacturing (AM) shows significant promise, applying this method in wire arc additive manufacturing (WAAM) processes poses various considerable challenges, including porosity, delamination, surface oxidation, etc. The limited research on WAAM of copper alloys, especially Cu1897, highlights the need for a more in-depth investigation. This study addresses the effects of process parameters in pulse cold metal transfer (CMT)-based WAAM of Cu1897, i.e., pulse correction (PC) and arc length correction (ALC), on bead penetration and porosity. The results showed that as PC was increased from −5 to +5, weld bead penetration increased from 2.38 mm to 3.87 mm. To further enhance penetration and reduce the porosity, the ALC was varied from +30% to −30% with a step size of 15%. The results showed that weld bead penetration increased to 4.47 mm by altering the ALC from +30% to −30%. Additionally, as the ALC varied within this range, porosity decreased significantly from 3.98% to 0.28%. Overall, it is concluded that a lower value of ALC is recommended to improve bead penetration and reduce porosity in WAAM of Cu1897.

This study is devoted to the investigation of combustion characteristics of aluminized solid propellants (SPs) with ammonium nitrate (SP4, 44 wt.% and SP5, 66 wt.%), ammonium perchlorate (5 wt.%), and inert (butyl rubber) and active (polyvinyl tetrazole) binders. The experimental SP formulations were compared with their analogs, both with and without ammonium nitrate included in their compositions. Among ammonium nitrate–contained SPs, the following row of burning rates was found (ammonium nitrate content in brackets, wt.%): SP3 (0) > SP2 (44) ∼ SP4 (44) > SP1 (51) > SP5 (66).The studied SPs were modified by additives of micron‐sized oxide powders (Co₃O₄, V₂O₅, MnO₂, Fe₂O₃, CuO) and bichromate salts (K₂Cr₂O₇, Na₂Cr₂O₇, (NH₄)₂Cr₂O₇) or potassium bichromate in combination with the second salt of different origin: oxalates (NH₄)₂C₂O₄, La₂(C₂O₄)₃, and Na₂C₂O₄ and chlorides NaCl, KCl, and BaCl₂.Micron‐sized oxide powders were added into the formulation SP4 with 44 wt.% of ammonium nitrate. It was found that there was a 20–30% improvement in the burning rate. CuO exhibited the most pronounced catalytic effect, increasing the burning rate by up to 270% compared to the SPs without additives. K₂Cr₂O₇ was the effective combustion modifier for ammonium nitrate–based SPs, enhancing the burning rate by up to 100% in the pressure range above 4 MPa. The addition of BaCl₂ and La₂(C₂O₄)₃ in the pressure range from 2 to 5 MPa had a promoting effect on K₂Cr₂O₇.The studied salt mixtures based on K₂Cr₂O₇ were found to be effective catalysts for AN‐based SP combustion.

Glass offers unique advantages such as high optical transparency, thermal stability, and chemical resistance, making it indispensable in optics, microelectronics, sensing, and biomedical applications. However, its high melting point, brittle nature, and incompatibility with traditional manufacturing methods present significant fabrication challenges. Additive manufacturing (AM) introduces new possibilities for the glass industry by enabling the fabrication of customised, complex 3D structures and the integration of glass with other compatible materials. In particular, multi-material glass additive manufacturing (MMGAM) has emerged as a promising frontier, enabling both the spatial tuning of glass composition, dopants, and functionalities, as well as the co-fabrication of glass with dissimilar materials, such as polymers, metals, or ceramics, within a single component using integrated AM platforms. This paper provides a comprehensive overview of the current state of MMGAM, structured around four key themes: (i) key material properties and interfacial compatibility considerations, (ii) AM techniques adapted for multi-material glass systems, (iii) material combinations and strategies for functional integration, and (iv) future challenges and research directions. Particular emphasis is placed on the challenges of interfacial bonding, material compatibility, and the formulation of printable glass systems suitable for co-processing with other materials. The review explores recent strategies for enabling multifunctional, integrated architectures that combine optical, structural, or chemical functionalities within a single component. By synthesising current advances and outlining key research gaps, this work aims to accelerate the development and broader adoption of MMGAM technologies.