Experimental Application of Robotic Wire-and-Arc Additive Manufacturing Technique for Strengthening the I-Beam Profiles

Abstract

In recent years, the use of Wire-and-Arc Additive Manufacturing (WAAM) for strengthening standardized steel elements received significant interest within the research community. The reason for this lies in the theoretical potential of WAAM to improve the economic and environmental aspects of contemporary steel construction through efficient material consumption. As efficiency is often obtained through detailed design study, the paper presents a design exploration of suitable stiffener geometries under the assumption of infinite geometrical freedom. The assumption is eventually invalidated as process constraints specific to the generated geometries emerge from test trials. Once identified, process constraints are documented and overcome through adequate and precise path planning. Feasibility analysis is an important step between design and fabrication, especially in the case of large-scale or geometrically complex components. With reference to the case of stiffeners, a feasibility analysis is necessary to take into account the specific geometrical limits of the build volume, which is not typically the case for conventional WAAM fabrication. The current research provides the first investigation to understand the means for future on-site WAAM strengthening of existing steel structural elements.

Additive Manufacturing – New Trends and Market Analysis

“…In the first group studies on different applications are ongoing both for characterization of complete members [8], [9] as well as to predict the behavior of WAAM locally reinforced elements [10], [11], [12] or topology optimized applications [13], [14], [15].…”

“…a) Stiffening of columns[10] b) Stiffening of I beam[11] c) Stiffening of slender plates[12] Local reinforcing of elements…”

Stiffening of slender plates using Wire Arc Additive Manufacturing

“…AM strengthening has been developed by considering use of wire-and-arc additive manufactured (WAAM) stiffener (Figure 1) on one side of the plate. Similar solutions were explored for stiffening of I-beam web [5] or body reinforcement of automotive engineering [6]. In this paper, different arrangements of WAAM plate stiffeners and comparison to traditional prismatic stiffener are investigated.…”

Serial Uniqueness: Strengthening Standard Steel Profiles with WAAM Technology

“…Current works on strengthening with WAAM have been applied to I-beams (3,4) and panels (5). WAAM in combination with serial industrial elements that are produced with standard rolling methods could create a distinguished hybrid manufacturing method that combines cross-section optimisation with optimisation at the structural element level for the purpose of efficient use of the material.…”