Design, fabrication and mechanical characterization of a structural node made using Wire and Arc Additive Manufacturing (WAAM) technology

Additive Manufacturing (AM), also known as “3D printing”, is a recent production technique that allows the creation of three-dimensional elements by depositing multiple layers of material. This technology is widely used in various industrial sectors, such as automotive, aerospace and aviation. With AM, it is possible to produce particularly complex elements for which traditional techniques cannot be used. These technologies are not yet widespread in the civil engineering sector, which is slowly changing thanks to the advantages of AM, such as the possibility of realizing elements without geometric restrictions, with less material usage and a higher efficiency, in particular employing Wire-and-Arc Additive Manufacturing (WAAM) technology. Buildings that benefit most from AM are all those structures designed using form-finding and free-form techniques. These include gridshells, where joints are the most critical and difficult elements to design, as the overall behaviour of the structure depends on them. It must also be considered that, during the design, the engineer must try to minimize the structure's own weight. Self-weight reductions can be achieved by Topological Optimization (TO) of the joint itself, which generates complex geometries that could not be made using traditional techniques. To sum up, weight reductions through TO combined with AM allow for several potential benefits, including economic ones. In this thesis, the roof of the British Museum is considered as a case study, analysing the gridshell structure of which a joint will be chosen to be designed and manufactured, using TO and WAAM techniques. Then, the designed joint will be studied in order to understand its structural behaviour in terms of stiffness and strength. Finally, a printing test will be performed to assess the production feasibility using WAAM technology. The computational design and fabrication stages were carried out at Technische Universität Braunschweig in Germany.

Experimental and numerical characterization of flame instability in hydrogen-containing flames

In the framework of the energy transition, the acquisition of proper knowledge of fundamental aspects characterizing the use of alternative fuels is paramount as well as the development of optimized know-how and technologies. In this sense, the use of hydrogen has been indicated as a promising route for decarbonization at the end-users stage in the energy supply chain. However, the elevated reactivity and the low-density at atmospheric conditions of hydrogen pose new challenges. Among the others, the dilution of hydrogen with carbon dioxide from carbon capture and storage systems represents a possible route. However, the interactions between these species have been poorly studied so far. For these reasons, this thesis, in collaboration between the University of Bologna and Technische Universität Bergakademie of Freiberg in Saxony (Germany), investigates the laminar flame of hydrogen-based premixed gas with the dilution of carbon dioxide. An experimental system, called a heat flux burner, was adopted ad different operating conditions. The presence of the cellularity phenomenon, forming the so-called cellular flame, was observed and analysed. Theoretical and visual methods have allowed for the characterization of the investigated flames, opening new alternatives for sustainable energy production via hydrogen transformation.