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.

Analisi di pushover 3D per strutture in c.a.

In the present study, a new pushover procedure for 3D frame structures is proposed, based on the application of a set of horizontal force and torque distributions at each floor level; in order to predict the most severe configurations of an irregular structure subjected to an earthquake, more than one pushover analysis has to be performed. The proposed method is validated by a consistent comparison of results from static pushover and dynamic simulations in terms of different response parameters, such as displacements, rotations, floor shears and floor torques. Starting from the linear analysis, the procedure is subsequently extended to the nonlinear case. The results confirm the effectiveness of the proposed procedure to predict the structural behaviour in the most severe configurations.

Time-dependent behaviour of reinforced concrete slabs

In this thesis is studied the long-term behaviour of steel reinforced slabs paying particular attention to the effects due to shrinkage and creep. Despite the universal popularity of using this kind of slabs for simply construction floors, the major world codes focus their attention in a design based on the ultimate limit state, restraining the exercise limit state to a simply verification after the design. For Australia, on the contrary, this is not true. In fact, since this country is not subjected to seismic effects, the main concern is related to the long-term behaviour of the structure. Even if there are a lot of studies about long-term effects of shrinkage and creep, up to date, there are not so many studies concerning the behaviour of slabs with a cracked cross section and how shrinkage and creep influence it. For this reason, a series of ten full scale reinforced slabs was prepared and monitored under laboratory conditions to investigate this behaviour. A wide range of situations is studied in order to cover as many cases as possible, as for example the use of a fog room able to reproduce an environment of 100% humidity. The results show how there is a huge difference in terms of deflections between the case of slabs which are subjected to both shrinkage and creep effects soon after the partial cracking of the cross section, and the case of slabs which have already experienced shrinkage effects for several weeks, when the section has not still cracked, and creep effects only after the cracking.

On the characterization of the mechanical behaviour of bonded steel-CFRP adhesive joints

The use of adhesively bonded carbon fiber reinforced polymers (CFRP) is well established to repair metallic structural elements in the aerospace industry for more than three decades. Despite a few exceptions, this technology has yet not been exploited for the steel construction industry where there is a great need to rehabilitate old metallic bridges. For instance, in Europe more than 30% of the railway bridge stock operated for more than 100 years. These bridges are made of old mild steel or puddle iron that exhibits poor behaviour due to the quality of the material itself and degradation caused by the long-term loading or environmental effects. The modest results for Steel/CFRP joints obtained may be due to the type of adhesive used. In fact, most of the previous studies utilized brittle adhesives specially developed for concrete structures. Recent ductile adhesives that made for the automotive industry for metallic joints should be more appropriate. In this study, an experimental investigation on the behaviour of CFRP/steel adhesively bonded joints is presented. A comparison between brittle adhesives and ductile adhesives is conducted. The results show that the ductile adhesives achieve much higher performance than the brittle ones. The brittle adhesives provide more stiffness to the adhesive joint. In the specimens with the ductile adhesives, the failure pattern started by yielding the steel bars first then the adhesive joint which is promising since it can facilitate the design significantly if the steel yielding can be used as a design criterion. The main disadvantage of ductile adhesives is they are usually more expensive than brittle ones. In order to solve this issue, bi-adhesive joints, in which the joint is mainly made of (low cost) brittle adhesive and ductile adhesive in the stress concentration region, are proposed. The results revealed very high improvement up to the yielding strength of the steel bars and with a balanced stiffness.