Optimisation and testing of wire arc additively manufactured steel stub columns

Meng, Xin; Weber, Ben; Nitawaki, Masashi; Gardner, Leroy

doi:10.1016/j.tws.2023.110857

Cited by 31 publications

(5 citation statements)

References 54 publications

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“…Two different grades of welding wires, namely ER70S-6 and ER110S-G, were chosen for the printing of the beams, with the higher steel grade utilised in the regions with greater demands of bending moment capacity. A quad-linear model [10], based on the existing test data on similar material [6], was utilised to simulate the stress-strain relationship associated with ER70S-6, while stress-strain curve, determined from tensile coupon tests [8] were employed for ER110S-G. Four different printable thicknesses, namely 3.5, 5.0, 6.0 and 8.0 mm, were chosen. The overall goal of the optimisation was to minimise self-weight and material costs without reducing the load-carrying capacity.…”

Section: Optimisation Of Simply-supported Waam Beamsmentioning

confidence: 99%

“…A series of contours with a spacing of 0.1 mm along the length, which was shown to be suitable for accurately capturing the geometric undulations of typical WAAM elements without creating unnecessarily large data sets [8,15], were extracted, as shown in Figure 3. The outer cross-section height H and breadth B were calculated based on the point pairs around each contour, as illustrated in Figure 3, while the area enclosed by the outer contour A was directly determined from the contour.…”

Section: Geometric Propertiesmentioning

confidence: 99%

“…Experimental studies on the structural behaviour of WAAM elements are not as prominent as studies on the behaviour of WAAM material. Early physical tests have been carried out to investigate their local buckling [8] and the bending behaviour [9]. These studies mainly featured conventional structural profiles to enable direct comparisons with the behaviour of traditionally manufactured members.…”

Section: Introductionmentioning

confidence: 99%

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Optimisation and testing of simply‐supported WAAM beams

Weber,

Meng,

Nitawaki

et al. 2023

ce papers

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The design and performance of optimised wire and arc additively manufactured (WAAM) rectangular hollow section (RHS) beams, with varying material strengths and thicknesses along their lengths, are investigated in this study. Simply‐supported beams under three‐point bending were considered. Size optimisation of the RHS beams was carried out by fixing the nominal outer profile and varying the local thicknesses and steel grades in discrete steps to accommodate the variation of the bending moment along the member length. Two optimised beam specimens were manufactured via WAAM and tested, and were shown to have excellent load‐carrying capacities at greatly reduced self‐weights compared with the conventionally manufactured beams, indicating a considerable increase in their structural efficiency. This study confirms the feasibility of combining materials with different thicknesses and steel grades using WAAM, which provides structural engineers with further design freedom and opportunities to minimise material use.

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Section: Optimisation Of Simply-supported Waam Beamsmentioning

confidence: 99%

Section: Geometric Propertiesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Optimisation and testing of simply‐supported WAAM beams

Weber,

Meng,

Nitawaki

et al. 2023

ce papers

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“…In [3], the 3D laser scanning technique was employed to examine WAAM steel square hollow section (SHS) specimens. The raw point clouds were initially gridded with a spacing of 0.2 mm, and key cross-section dimensions, including the height H, breadth B, wall thickness and crosssectional area of the examined WAAM SHS specimens were obtained by analysing contours of the scans at 0.2 mm intervals along the longitudinal direction, as illustrated in Figure 4.…”

Section: Dimensional Propertiesmentioning

confidence: 99%

“…3D scanning has also been increasingly utilised in structural testing, primarily for the determination of dimensional properties and characterisation of initial geometric imperfections. With the growing research interest in metal additive manufacturing, particularly wire arc additive manufacturing (WAAM), 3D scanning becomes crucial for capturing the unique geometric features inherent to the printing process [3]. Further discussions on its use in structural experiments are provided in Section 3.…”

Section: Introductionmentioning

confidence: 99%

Applications of 3D scanning and digital image correlation in structural experiments

Meng,

Pullen,

Guo

et al. 2023

ce papers

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The primary aim of the present study is to explore the use, advantages and potential of two advanced data acquisition techniques – 3D scanning and digital image correlation (DIC), in the testing of metallic structures. 3D scanning is a novel method for capturing the full outer geometry of an object. It is being increasingly used in experimental studies for the determination of dimensional parameters and the characterisation of local and global imperfections, examples of which are given and discussed. Digital image correlation (DIC) is a rapidly evolving technology for the full‐field measurement of the displacements and strains over a surface. A brief introduction to DIC and its workflow is firstly provided. Example applications of DIC in various scales of experiments, including material tests, structural element tests and full‐scale structural system tests, are subsequently discussed. These new‐generation data acquisition techniques enable structural researchers to gain a deeper insight into the behaviour of metallic structures in experimental research.

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