Reinforced Particle-Bed Printing by Combination of the Selective Paste Intrusion Method with Wire and Arc Additive Manufacturing – A First Feasibility Study

Weger, Daniel; Baier, Daniel; Straßer, Alexander; Prottung, Sophia; Kränkel, Thomas; Bachmann, Andreas; Gehlen, Christoph; Zäh, Michael F.

doi:10.1007/978-3-030-49916-7_95

Cited by 25 publications

(37 citation statements)

References 16 publications

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“…In this first demonstrator, only horizontal reinforcement was integrated, whereas further investigations must also address reinforcements perpendicular to the layer orientation. For this, a suitable combination would be with the Wire Arc Additive Manufacturing process, in which the reinforcement would be built up simultaneously layer by layer using droplets of steel [ 64 ].…”

Section: Discussionmentioning

confidence: 99%

Large Particle 3D Concrete Printing—A Green and Viable Solution

et al. 2021

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The Large Particle 3D Concrete Printing (LP3DCP) process presented in this paper is based on the particle bed 3D printing method; here, the integration of significantly larger particles (up to 36 mm) for selective binding using the shotcrete technique is presented. In the LP3DCP process, the integration of large particles, i.e., naturally coarse, crushed or recycled aggregates, reduces the cement volume fraction by more than 50% compared to structures conventionally printed with mortar. Hence, with LP3DCP, the global warming potential, the acidification potential and the total non-renewable primary energy of 3D printed structures can be reduced by approximately 30%. Additionally, the increased proportion of aggregates enables higher compressive strengths than without the coarse aggregates, ranging up to 65 MPa. This article presents fundamental material investigations on particle packing and matrix penetration as well as compressive strength tests and geometry studies. The results of this systematic investigation are presented, and the best set is applied to produce a large-scale demonstrator of one cubic meter of size and complex geometry. Moreover, the demonstrator features reinforcement and subtractive surface processing strategies. Further improvements of the LP3DCP technology as well as construction applications and architectural design potentials are discussed thereafter.

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Section: Discussionmentioning

confidence: 99%

Large Particle 3D Concrete Printing—A Green and Viable Solution

et al. 2021

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“…Test results showed that the ductility and bond strength of printed steel bars was similar to that of the conventional steel bars. Weger et al [ 219 ] also observed that reinforcement with complex geometries can be produced using wire and arc additive manufacturing followed by selective paste intrusion to bond cementitious composite with the printed reinforcement. Katzer and Szatkiewicz [ 220 ] printed plastic formwork with the ribbed structures as a substitute for steel reinforcement of 3D-printed concrete.…”

Section: Reinforcement Strategies For Concrete 3d Printingmentioning

confidence: 99%

3D Concrete Printing: A Systematic Review of Rheology, Mix Designs, Mechanical, Microstructural, and Durability Characteristics

2021

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This paper provides a state-of-the-art report on the up-to-date research on the emerging 3D concrete printing technology from the concrete materials perspective. It reviews the recent research focused on understanding and characterizing the rheological necessities of the concrete printing process and discusses how the researchers are tailoring compatible mix proportions for the 3D concrete printing process by using eco-friendly binders, waste aggregates, chemical admixtures, and nano-additives. This paper systematically evaluates anisotropic behavior in the mechanical properties of printed concrete and establishes an order for anisotropic behavior in the compressive, flexural, and tensile strengths along three different axes (X, Y, and Z axes) of printed concrete. It evaluates the ratio of flexural strength to the compressive strength of printed concrete along the above three axes. This article explains the influence of variation of printing process parameters on the mechanical properties and discusses reinforcement approaches used for increasing structural performance. The microstructure at the interface of adjacent layers and also at the interface of the reinforcement-cement matrix is discussed. The recent research on the durability performance of printed concrete is critically discussed and future research needs for 3D concrete printing are identified in this paper.

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“…However, the integration in the layerwise production of the concrete 3D-printing is a challenge, which has not been satisfactorily solved yet. Weger et al present the first results on the temperatures that occur during the layerwise welding process and the impact on the properties of cementitious systems [26].…”

Section: Reinforcement Systems For Extrusion (State Of the Art)mentioning

confidence: 99%

Interlayer Reinforcement Combined with Fiber Reinforcement for Extruded Lightweight Mortar Elements

et al. 2020

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Lightweight mortar extrusion enables the production of monolithic exterior wall components with improved thermal insulation by installing air chambers and reduced material demand compared to conventional construction techniques. However, without reinforcement, the systems are not capable of bearing high flexural forces and, thus, the application possibilities are limited. Furthermore, the layer bonding is a weak spot in the system. We investigate a reinforcement strategy combining fibers in the mortar matrix with vertically inserted elements to compensate the layer bonding. By implementing fibers in the extruded matrix, the flexural strength can be increased almost threefold parallel to the layers. However, there is still an anisotropy between the layers as fibers are oriented during deposition and the layer bond is still mainly depending on hydration processes. This can be compensated by the vertical insertion of reinforcement elements in the freshly deposited layers. Corrugated wire fibers as well as short steel reinforcement elements were suitable to increase the flexural strength between the layers. As shown, the potential increase in flexural strength could be of a factor six compared to the reference (12 N/mm2 instead of 1.9 N/mm2). Thus, the presented methods reduce anisotropy in flexural strength due to layered production.

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Reinforced Particle-Bed Printing by Combination of the Selective Paste Intrusion Method with Wire and Arc Additive Manufacturing – A First Feasibility Study

Cited by 25 publications

References 16 publications

Large Particle 3D Concrete Printing—A Green and Viable Solution

Large Particle 3D Concrete Printing—A Green and Viable Solution

3D Concrete Printing: A Systematic Review of Rheology, Mix Designs, Mechanical, Microstructural, and Durability Characteristics

Interlayer Reinforcement Combined with Fiber Reinforcement for Extruded Lightweight Mortar Elements

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