I-section steel columns strengthened by wire arc additive manufacturing - concept and experiments

Wire arc additive manufacturing (WAAM) is a method of metal 3D printing which, when strategically combined with traditional methods of manufacture, has the potential to make a significant impact on the construction sector. To illustrate this potential, an experimental investigation into the flexural buckling response of 15 hot-rolled I-section columns, strengthened by WAAM, has been undertaken and is presented herein. The WAAM material was added at the flange tips and distributed non-uniformly along the member length. Complementary tensile coupon tests on the I-section and WAAM steel material were also carried out. 3D laser scanning was employed to determine the geometry and global geometric imperfections of all specimens, while digital image correlation measurements were taken to provide a detailed insight into the surface deformation characteristics of the specimens during testing. The WAAM stiffeners provided three mechanisms of strengthening: (1) increased cross-sectional area and second moment of area, (2) enhanced local buckling capacity and (3) a more favourable residual stress pattern. Disproportionately high increases in axial capacity of between 17% and 54% for relatively modest increases of mass between 2% and 26% (of the weight of the strengthened I-section column) were achieved, demonstrating, for the first time, the substantial benefits in terms of enhanced structural efficiency and material savings, that can be realised by the combination of WAAM with traditional manufacturing methods. In the best case, the efficiency of the WAAM material (in terms of increase in load-bearing capacity per unit mass) was almost eight times that of the bare steel section. The described hybrid manufacturing concept can be employed to improve the performance and reduce the environmental impact of structures and could be a game changer in both new construction and the rehabilitation of existing infrastructure.