Twinned dendrites have attracted worldwide attention in the past half century due to their unusual orientation and crystallographic symmetry. Successive research has established a basic understanding of them in relatively steady processes like direct chill casting and directional solidification. This work, for the first time, investigated the growth behaviors of twinned dendrites in the wire arc directed energy deposition. The crystallographic characteristics, formation, and evolution laws of the twinned dendrites in the unsteady localized solidification condition are explored via experiments and numerical simulations. Results show that stacking faults are vital in the longitudinal growth of twinned dendrites by adjusting intermittent twin boundaries. During deposition, Mg, Zn, and Cu, which have low stacking fault energy, can promote the growth of twinned dendrites. The molten pool tail has large temperature gradients, crystallization velocities, and sufficient convection, providing advantageous growth conditions for twinned dendrites. Competitive relationships form between twinned and regular dendrites at the molten pool center. However, the twinned dendrites also cooperate with regular dendrites in epitaxial growth via their 〈100〉 lateral branch. With the remelting depth increasing, the twinned dendrite morphology changes from lamellar to isolated unilateral feather shape, then to unchained islands, and finally disappear.
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