Wire arc directed energy deposition (WADED) represents an appealing approach for producing complex, large-scale, and three-dimensional metallic components from metallic wire, guided by computer-aided design models. In the additive manufacturing process, where components are incrementally constructed layer upon layer, the deposited material experiences a recurring series of temperature fluctuations, essentially undergoing reheating cycles. This study harnesses the inherent heat treatment (IHT) mechanism, characterized by these cyclic reheating phenomena, to orchestrate in situ grain growth partial aging, and non-uniform precipitation of intermetallic compounds during the WADED process of Al-Cu alloy. Consequently, following IHT, as the average grain size expanded from 26.1 μm to 40.1 μm, the micro-hardness and tensile capabilities of the as-deposited alloy exhibited a decline. However, by applying a subsequent solution treatment coupled with a 16-hour aging period, the microstructural variations were significantly mitigated, leading to an enhancement in the mechanical properties of the alloy. [ABSTRACT FROM AUTHOR]

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