In　this　research,　four　different　arc　modes　including　conventional　cold　metal　transfer　(CMT),　CMT-pulse　(CMT-P),　CMT-Advanced(CMT-ADV)　and　CMT　pulse　advanced　(CMT-PADV)　were　used　to　deposit　2219-Al　wire.　The　effects　of　different　arc　modes　on　porosity,　pore　size　distribution　and　mechanical　properties　were　given　a　thorough　analysis.　A　number　of　multilayer　thin-wall　parts　were　fabricated　to　verify　the　suitable　arc　mode　for　the　fabrication　of　2219-Al　alloy　with　excellent　mechanical　properties.　The　statistical　analysis　of　the　porosity　and　the　size　distribution　indicated　that　the　CMT-PADV　process　gave　the　smallest　pore　area　percentage,　aspect　ratio　and　had　almost　no　larger　pores.　The　tensile　strength　could　reach　to　280MPa　for　the　as　deposited　2219-Al　samples　both　in　horizontal　and　vertical　directions　by　the　CMT-PADV　arc　mode.　In　addition,　large　2219-Al　metal　parts　were　fabricated　by　the　most　suitable　arc　mode.　Copyright　©　2018　MS&T18®