Abstract: To meet the demand for real-time collaborative regulation of process parameters during the forming of aluminum alloy frame components in the aerospace field, systematic research was conducted on the ultra-frequency pulsed TIG (UFP-TIG) wire-arc additive manufacturing process. The variation law of component interlayer temperature under different process parameters was investigated, and the optimal interlayer temperature control range of 80±5 ℃ was determined. At wire feeding speeds of 5, 6 and 7m/min respectively, the matching ranges of welding current and welding torch travel speed were obtained, which enable continuous and stable liquid bridge transfer of molten droplets with the single-layer deposition height controlled within 2~3 mm. Process experiments were designed using the regression combinatorial design method, and a mathematical model correlating process parameters with component dimensions was established. Verification tests were carried out under different wire feeding directions and on variable-wall-thickness specimens. The results show that the maximum relative height difference of formed components under different wire feeding directions is less than 6.6%, and the height difference between the thick-wall and thin-wall sections of the variable-wall-thickness specimen is only 2.20%, which verifies the applicability and feasibility of the established model. The proposed process method provides technical support for the selection and optimization of process parameters for aluminum alloy UFP-TIG wire-arc additive manufacturing.