Manjhi, S.K.Sekar, P.Bontha, S.Balan, A.S.S.2026-02-042023CIRP Journal of Manufacturing Science and Technology, 2023, 46, , pp. 48-6417555817https://doi.org/10.1016/j.cirpj.2023.07.008https://idr.nitk.ac.in/handle/123456789/21645Wire arc additive manufacturing (WAAM) has drawn tremendous attention for manufacturing large and complex components of lightweight material at a moderate cost due to its high deposition rate and energy efficiency. Generally, WAAM-Mg alloy comprises columnar and columnar dendrite grains due to high cooling rates and thermal gradients responsible for anisotropic mechanical properties. To overcome this challenge, in this work, CMT-WAAM, which generally uses comparatively low heat input (33% lower than conventional WAAM), was used to deposit AZ31 Mg thin wall. The metallurgical characterization of the deposited thin wall of the top (T), middle (M) and bottom (B) sections reveals equiaxed grains of average sizes ∼ 58, ∼ 63 and ∼ 38 µm, respectively. In addition, TEM results exhibit the formation of secondary phase particles, i.e., β-Mg<inf>17</inf>Al<inf>12</inf> and ɳ-Al<inf>8</inf>Mn<inf>5</inf>. Further, the ultimate tensile strength (UTS) and % elongation (% EL) in the travel direction (UTS = 224 MPa, % EL= 23.47%) are superior to that obtained in the build direction (UTS = 217 MPa, % EL = 20.82%). The corrosion resistance of WAAMed AZ31 Mg alloy is higher than wrought (cold rolled) AZ31 Mg alloy in Hank's balanced salt solution (HBSS). The results of this study reveal the potential of CMT-WAAM to deposit different grades of Mg with desired microstructure, mechanical properties and corrosion resistance. © 2023 CIRPAdditivesCold rollingCorrosion resistanceCorrosion resistant alloysCorrosion resistant coatingsCorrosive effectsDeposition ratesDepositsEnergy efficiencyMagnesium alloysMetal claddingTensile strengthTexturesThin walled structuresWalls (structural partitions)WireAZ31 Mg alloysCold metal transfersCorrosion behaviourEqui-axed grainsLarge componentsSecondary phase particlesThin wallsUltimate tensile strengthWire arcWire arc additive manufacturing3D printing