Additive manufacturing of catenary arch structure design: Microstructure, mechanical properties and numerical simulation

The lightweight structural design seeks to minimize component weight while maintaining adequate mechanical properties. Drawing inspiration from the principles of arch bridge construction, this study integrates these concepts into additive manufacturing, leading to the development of a catenary arch structure. The WC/High Entropy Alloy composites (WC/HEA) catenary arch structure, distinguished by its variable spans and heights, was fabricated using selective laser melting (SLM) technology. An analysis of the compression behavior and mechanical properties of the WC/HEA catenary arch structure under compressive loads was conducted through a combination of finite element analysis and experimental methods, alongside an assessment of its bending characteristics. The results show that catenary arch structure can reduce the weight of members by 20–60%. L 2 F 0.25 structure shows excellent mechanical properties, compressive ultimate strength reaches 1027.1 MPa, yield strength reaches 715.9 MPa, bending ultimate strength reaches 1519.4 MPa, yield strength reaches 1233.9 MPa; The main fracture mode of the sample with 26.57° shear Angle is vertical collapse, and the main fracture mode of the catenary arch structure with 37° and 45° shear Angle is inclined shear fracture.