3‐D‐Printing with Steel: Additive Manufacturing of Connection Elements and Beam Reinforcements

Feucht, Thilo; Lange, Jörg; Erven, Maren

doi:10.1002/cepa.1064

Cited by 21 publications

(16 citation statements)

References 3 publications

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“…WAAM has a high potential for an application in the field of connections, where little material is needed and this material might be subject to great geometrical variation [7]. Furthermore wherever great savings in material due to topology optimization are possible WAAM will play an important role.…”

Section: Applicationsmentioning

confidence: 99%

3D‐Printing with Steel ‐ Additive Manufacturing Connections and Structures

Lange¹,

Feucht²,

Erven³

2021

ce papers

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Automated production is finding its way into fabrication of structural steel. One robot holds attachments (stiffeners, head plates, etc.) to a steel beam or column and another robot produces weld seams. However, welding robots can also be used for additive manufacturing (Wire + Arc Additive Manufacturing, WAAM). The wire electrode serves as printing material. The Institute for Steel Construction and Materials Mechanics in Darmstadt is investigating how typical connecting elements of steel construction can be printed directly on steel beams using Additive Manufacturing with arc welding and robots. Furthermore structural elements like nodal points are printed and even complete structures like columns and a little bridge have been manufactured additively already. The main focus is on determining suitable welding and process parameters. In addition, topology optimization is used to find good structures using a low amount of material. This is possible due to the free design prospects of 3D‐printing. This opens for novel design and production strategies.

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Section: Applicationsmentioning

confidence: 99%

3D‐Printing with Steel ‐ Additive Manufacturing Connections and Structures

Lange¹,

Feucht²,

Erven³

2021

ce papers

Self Cite

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“…To justify that WAAM is an applicable manufacturing process for such a structure it was printed and tested afterwards. As WAAM is a quite young process there are no sets of parameters available like there are for plastic 3D-printers, for instance [5]. Especially for voluminous structures the former research was very limited [30][31][32].…”

Section: Topology Optimization Of the T-stubmentioning

confidence: 99%

3D‐Printing with steel of a bolted connection

Erven¹,

Lange²,

Feucht³

2021

ce papers

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Additive Manufacturing seems promising for the steel construction industry, especially for small components with complex shapes. With Wire‐and‐Arc‐Additive‐Manufacturing (WAAM) a process was found which is fast and cheap compared to other Additive Manufacturing processes for metals. Furthermore, arc‐welding is well known in steel construction industry. Bolted head plates are a common connection. Although they are relatively easy to produce, they are uneconomical in load transfer due to straining of the plates which are subject to bending. This type of connection is predestined for Additive Manufacturing. Rethinking the structure by taking into account the potentials of Additive Manufacturing brings a clear advantage compared to the conventional production. Thus, with a material saving of 60 % the same load capacity of the original flat head plate can be achieved. The paper shows how the new production process WAAM can significantly change the shape of structures on the example of a bolted head plate. Therefore, all steps from the original design to the manufactured structure are demonstrated, including the structure finding by using topology optimization, the manufacturing with different parameters and a first testing of the manufactured structures.

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“…WAAM has a high potential for applications in the field of connections, where little material is needed and this material might be subjected to great geometrical variation [11]. Furthermore, wherever great savings in material due to topology optimization are possible, WAAM will play an important role.…”

Section: Applicationsmentioning

confidence: 99%

3D printing with steel

2020

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Extended keynote paper of Eurosteel 2021 Automated production is finding its way into the fabrication of structural steel. One robot holds attachments (stiffeners, end plates, etc.) on a steel beam or column and another robot produces weld seams. However, welding robots can also be used for Additive Manufacturing (Wire and Arc Additive Manufacturing, WAAM). The wire electrode serves as a printing material. The Institute of Steel Construction and Materials Mechanics in Darmstadt is investigating how typical connecting elements for steel structures can be printed directly on steel beams using Additive Manufacturing with arc welding and robots. Furthermore, structural elements such as nodes for space frames can be printed and even complete structures, e.g. columns and a little bridge, have already been manufactured additively. The main focus is on determining suitable welding and process parameters. In addition, topology optimization is necessary in order to achieve good structures using a small amount of material. This is possible due to the free design prospects of WAAM, which opens up new design and production strategies.

show abstract

3‐D‐Printing with Steel: Additive Manufacturing of Connection Elements and Beam Reinforcements

Cited by 21 publications

References 3 publications

3D‐Printing with Steel ‐ Additive Manufacturing Connections and Structures

3D‐Printing with Steel ‐ Additive Manufacturing Connections and Structures

3D‐Printing with steel of a bolted connection

3D printing with steel

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