Development of residual stress of high magnitude, to the extent of material yield strength and in some cases higher than yield strength, is one of the major challenges faced by components produced using the wire arc additive manufacturing (WAAM). This study focuses on aluminum alloy 5183 with respect to the residual stress formation and distribution in WAAM builds. Residual stresses were determined using the contour method. The effects of processing conditions, such as substrate thickness, interlayer temperature, and deposit height on the magnitude and distribution of residual stresses were investigated. Substrate thickness was found to have a major influence on the residual stress distribution along deposit height. Tensile residual stress up to the value of the material yield strength was present. The majority part of the deposit showed tensile stress while substrate showed compensating compressive residual stress. Lower interlayer temperature samples exhibited residual stresses of higher degree of magnitude compared with sample produced using higher interlayer temperature. Deposit height, i.e., total number of layers affected stress distribution pattern similar to substrate thickness.

Additive manufacturing offers manufacturing flexibility for intricate components and also allows for precise control over the microstructure. This review paper explores the current state of the art in additive manufacturing techniques for Alnico permanent magnets, emphasizing the notable advantages and challenges associated with this innovative approach. Both the LPBF and L-DED processes have demonstrated promising results in fabricating Alnico with magnetic properties comparable with conventionally processed samples. The optimization of process parameters successfully reduced porosity and cracking in the LPBF processing of Alnico. The review further explored the significance of additive manufacturing process parameter optimization in managing the temperature gradient and solidification rate for a desired microstructure and enhanced magnetic properties. Other potential additive manufacturing methods suitable for the fabrication of Alnico were discussed, along with the challenges associated with the process. The insights provided also highlight how additive manufacturing holds the potential to replace post-processing techniques like solutionization, magnetic annealing, and tempering often necessary in Alnico production.