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This paper aims to investigate a novel additive manufacturing (AM) method for titanium alloy using Joule heat as the single heat source to melt TC4 wire, which intends to provide a new low-power, low-cost solution for the processing of titanium alloys.

When current flows through the wire and the substrate, Joule heat will be generated to melt the wire and join the wire with the substrate. By stacking the wire layer by layer, finally a part can be formed. The cross-sectional morphology, microstructure and hardness of TC4 single track deposits formed by Joule heat melting wire AM were investigated by various characterization methods.

The melting width and melting penetration decreased with the increase of printing speeds. There is no obvious change in single track morphology with the change of printing pressures. The melting width and melting penetration increased with the increase of printing currents. The observation of the internal microstructure of a single track reveals a decrease in grain size as printing speeds increase. The average hardness of the single track was about 363 HV, which is comparable to the hardness of the parts fabricated by selective laser melting process. The printing power is less than 300 W, which is lower than other AM processes.

This paper provides a novel solution for the processing of titanium alloy parts. Compared with other expensive energy sources, this work only uses an ordinary DC power supply as the energy source. The printing process is simple and the cost is low. The power is much lower than other AM processes.

The purpose of this paper is to review systematically the research of grey relation analysis (GRA) models.

Three different approaches, the springboard to build a GRA model, the angle of view in modelling, and the dimension of objects, are analysed, respectively.

The GRA models developed from the models based on relation coefficients of each point in the sequences in early days to the generalized GRA models based on integral or overall perspective. It evolved from the GRA models which measure similarity based on nearness, into the models which consider similarity and nearness, respectively. The objects of the research advanced from the analysis of relationship among curves to that among curved surfaces, and further to the analysis of relationship in three‐dimensional space and even the relationship among super surfaces in n‐dimensional space.

The further research on GRA models is proposed. One is about the property of GRA model. An in‐depth knowledge about the properties of GRA model will help people to understand its function, applicable area and requirements for modelling. The other one is about the extension of research object system. The object to be analysed should be extended from the common sequence of real numbers to grey numbers, vectors, matrices, and even multi‐dimensional matrices, etc.