Strength and ductility of corroded strands within the framework of safety assessment of existing bridges

Existing bridges built in the last 50 years face challenges due to states far different than those envisaged when they were designed, due to increased loads, ageing of materials, and poor maintenance. For post-tensioned bridges, the need emerged for reliable engineering tools for the evaluation of their capacity in case of steel corrosion due to lack of mortar injection. This can lead to sudden brittle collapses, highlighting the need for proper maintenance and monitoring. This thesis proposes a peak strength model for corroded strands, introducing a “group coefficient” that aims at considering corrosion variability in the wires constituting the strands. The application of the introduced model in a deterministic approach leads to the proposal of strength curves for corroded strands, which represent useful engineering tools for estimating their maximum strength considering both geometry of the corrosion and steel material parameters. Together with the proposed ultimate displacement curves, constitutive laws of the steel material reduced by the effects of corrosion can be obtained. The effects of corroded strands on post-tensioned beams can be evaluated through the reduced bending moment-curvature diagram accounting for these reduced stress-strain relationships. The application of the introduced model in a probabilistic approach allows to estimate peak strength probability functions and consecutive design-oriented safety factors to consider corrosion effects in safety assessment verifications. Both approaches consider two procedures that are based on the knowledge level of the corrosion in the strands. On the sidelines of this main research line, this thesis also presents a study of a seismic upgrading intervention of a case-study bridge through HDRB isolators providing a simplified procedure for the identification of the correct device. The study also investigates the effects due to the variability of the shear modulus of the rubber material of the HDRB isolators on the structural response of the isolated bridge.

IDeS methodology applied to automotive component re-engineering focused on lightweight and high-strength by additive manufacturing

The project aims to gather an understanding of additive manufacturing and other manufacturing 4.0 techniques with an eyesight for industrialization. First the internal material anisotropy of elements created with the most economically feasible FEM technique was established. An understanding of the main drivers for variability for AM was portrayed, with the focus on achieving material internal isotropy. Subsequently, a technique for deposition parameter optimization was presented, further procedure testing was performed following other polymeric materials and composites. A replicability assessment by means of the use of technology 4.0 was proposed, and subsequent industry findings gathered the ultimate need of developing a process that demonstrate how to re-engineer designs in order to show the best results with AM processing. The latest study aims to apply the Industrial Design and Structure Method (IDES) and applying all the knowledge previously stacked into fully reengineer a product with focus of applying tools from 4.0 era, from product feasibility studies, until CAE – FEM analysis and CAM – DfAM. These results would help in making AM and FDM processes a viable option to be combined with composites technologies to achieve a reliable, cost-effective manufacturing method that could also be used for mass market, industry applications.