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• Ti 2 AlNb-based alloys are in-situ manufactured by DWAAM technology. • Hot-wire technology is introduced to overcome the problem of the obvious difference in physical properties between two wires. • Composition distribution and macrosegregation mechanism of the in-situ prepared alloy are revealed. • Microstructure and mechanical properties of the in-situ prepared alloy are studied. • The integration of material-preparation and parts-processing is attractive for industrial production. For the reason of high temperature strength, high oxidation resistance and low density, Ti 2 AlNb-based alloy is expected to replace nickel-based alloy in the range of working temperature 600–800 °C and become a new generation of high-temperature structural alloys in the aerospace industry. However, Ti 2 AlNb-based alloys have great high-temperature deformation resistance and high brittleness, which greatly restricts its preparation and processing using traditional technology. In this research, an innovation method named double-wire arc additive manufacturing technology was adopted to in-situ manufacture Ti-22Al-24Nb (at%) alloy, and the TiNb and pure Al wire with designed feeding speed were taken as raw materials. The deposited component was investigated systematically. Results show that the composition error between the average testing value and designed value are under 1.1%, but there are also existing local segregation of composition and microstructure. The segregation phenomenon further deteriorates its mechanical properties, which means the ultimate tensile properties and elongation under room temperature and high temperature (650 °C) are 504 ± 38.59 MPa, 0.41 ± 0.03% and 375 ± 32.60 MPa, 0.76 ± 0.05% respectively on average. At the same time, the prepared alloy exhibits fully lamellar structure and XRD results show that the basic composition phases B2, O and α 2 of the Ti 2 AlNb-based alloy successfully appeared. The in-situ manufacturing method demonstrated in this work is expected to significantly promote the wider application of AM due to its low cost advantage and high flexibility. [ABSTRACT FROM AUTHOR]