64202 2025 eng 1 20 article Springer Science and Business Media LLC Cham 1 -- -- -- Wire arc directed energy deposition (DED-Arc) is an emerging metal additive manufacturing process to build near-net shaped metallic parts in a layer-by-layer with minimal material wastage. Automated in situ monitoring and fast-responsive analyses of process signatures and deposit profiles during DED-Arc are in ever demand to print dimensionally consistent parts and reduce post-deposition machining. A comprehensive experimental investigation is presented here involving real-time synchronous measurement of arc current, voltage, and the deposit profile using a novel multi-sensor monitoring framework integrated with the DED-Arc set-up. The recorded current–voltage transients are used to estimate the time-averaged arc power, and energy input in real time for an insight of the influence of wire feed rate and printing travel speed on the deposit characteristics. A unique attempt is made to represent the geometric profiles of the single-track deposits in a generalized mathematical form corresponding to a segmented ellipse, which has exhibited the minimum root-mean-square error of 0.03 mm. The dimensional inconsistency of multi-track deposits is evaluated quantitatively in terms of waviness using build profile monitoring and automated estimation, which is found to increase with an increase in step-over ratio and energy input. For the multi-track mild steel deposits, the suitable range of step-over ratio for the minimum surface waviness is observed to lie between 0.6 and 0.65. Collectively, the proposed framework of synchronized process monitoring and real-time analysis provides a pathway to achieve dimensionally consistent and defect-free parts, and highlights the potential for closed-loop control systems for a wider industrial application of DED-Arc. Progress in Additive Manufacturing 2363-9512 10.1007/s40964-025-01333-9 urn:nbn:de:kobv:b43-642029 true journal-article https://creativecommons.org/licenses/by/4.0 crossref doi-import false true 26.09.2025 Creative Commons - CC BY - Namensnennung 4.0 International Prashant Kumar Chaurasia Çağtay Fabry Andreas Pittner Amitava De Michael Rethmeier eng uncontrolled Additive Manufacturing eng uncontrolled Arc welding eng uncontrolled DED-arc eng uncontrolled Real-time monitoring and control eng uncontrolled Dimensional inconsistency Ingenieurwissenschaften und zugeordnete Tätigkeiten 9 Komponentensicherheit 9.3 Schweißtechnische Fertigungsverfahren Material Verlagsliteratur Datei für die Öffentlichkeit verfügbar ("Open Access") Wissenschaftliche Artikel der BAM Additive Fertigung Bundesanstalt für Materialforschung und -prüfung (BAM) https://opus4.kobv.de/opus4-bam/files/64202/Automated in Situ Monitoring and Analysis during DED-Arc.pdf