This study advances Wire Arc Additive Manufacturing (WAAM) by developing a low-cost, vision-based system for real-time melt pool monitoring, enhancing process stability and precision. It also explores the effects of heat treatment and friction stir processing on AZ31 magnesium alloy, focusing on porosity, microstructure, mechanical performance, and corrosion resistance. The integrated approach aims to optimize WAAM component quality through advanced monitoring, robotic contro