Recent Research on the Modelling and Reliability of Wire‐arc Additively Manufactured Steel Structures

Abstract The paper first presents a study of the material and geometric modelling of wire‐arc additively manufactured (WAAM) structural components. The material modelling is discussed with reference to tests of tension and compression coupons of as‐built and machined materials. Particular attention is paid to the role of the irregular surface geometry of as‐built materials and its influence on fracture initiation and propagation, leading to reduced ductility. Subsequently, recognising the potential for structural optimisation in the design of WAAM components, a comparison is presented of the structural performance of a beam‐column joint optimised for stiffness and strength using linear and fully nonlinear optimisation. The importance of using material and geometric nonlinear structural analysis when optimising for ultimate strength is demonstrated.