Enhancing Wire Arc Additive Manufacturing for Maritime Applications: Overcoming Operational Challenges in Marinel and Offshore Environments

The application of Wire Arc Additive Manufacturing for metal component fabrication on marine vessels and offshore platforms remains a significant challenge and an under-explored research domain. The primary obstacle lies in the dynamic and complex nature of the maritime environment, which imposes severe constraints on the operational stability of 3D printing systems. Methodologically, the article presents an analysis of the problems of using WAAM technology in the marine environment, as well as a theoretical analysis of the functionality, advantages and limitations of technical and software tools designed to improve the reliability of WAAM technology in marine conditions. The findings indicate that while WAAM offers notable adaptability and flexibility, maintaining print quality remains a challenge due to the high sensitivity of the process to fluctuations in thermal and mechanical conditions, particularly under the influence of shipborne vibrations. To accelerate the adoption of WAAM technology in maritime industries, this study synthesizes existing research aimed at improving instrumentation for effective WAAM implementation. Specific technical requirements for deploying WAAM on marine vessels are identified, alongside a critical assessment of current software and hardware solutions that could enhance the robustness of WAAM in offshore environments. Furthermore, recommendations are provided for advancing digital modeling, real-time monitoring, diagnostic methodologies, and process control to optimize WAAM for marine engineering applications. The study also delineates the functional properties of various metals suitable for WAAM-based manufacturing in maritime settings, highlighting their respective benefits and limitations. Ultimately, enhancing instrumentation for high-quality 3D printing is identified as a key driver for ensuring the competitiveness and innovation potential of WAAM technology in the maritime sector.