TY - JOUR A1 - Lange, Jörg A1 - Feucht, Thilo A1 - Erven, Maren T1 - 3D‐Printing with Steel ‐ Additive Manufacturing Connections and Structures JF - ce/papers: Proceedings in Civil Engineering N2 - Automated production is finding its way into fabrication of structural steel. One robot holds attachments (stiffeners, head plates, etc.) to a steel beam or column and another robot produces weld seams. However, welding robots can also be used for additive manufacturing (Wire + Arc Additive Manufacturing, WAAM). The wire electrode serves as printing material. The Institute for Steel Construction and Materials Mechanics in Darmstadt is investigating how typical connecting elements of steel construction can be printed directly on steel beams using Additive Manufacturing with arc welding and robots. Furthermore structural elements like nodal points are printed and even complete structures like columns and a little bridge have been manufactured additively already. The main focus is on determining suitable welding and process parameters. In addition, topology optimization is used to find good structures using a low amount of material. This is possible due to the free design prospects of 3D‐printing. This opens for novel design and production strategies. UR - https://doi.org/10.1002/cepa.1258 Y1 - 2021 UR - https://doi.org/10.1002/cepa.1258 UR - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:573-58559 SN - 2509-7075 VL - 4 IS - 2-4 SP - 2 EP - 7 PB - Ernst & Sohn CY - Berlin ER - TY - CHAP A1 - Feucht, Thilo A1 - Lange, Jörg ED - Zingoni, Alphose T1 - 3-D-printing with steel: Additive manufacturing of connection elements T2 - Advances in Engineering Materials, Structures and Systems: Innovations, Mechanics and Applications, Proceedings of the 7th International Conference on Structural Engineering, Mechanics and Computation (SEMC 2019) UR - https://doi.org/10.1201/9780429426506-75 Y1 - 2019 UR - https://doi.org/10.1201/9780429426506-75 SN - 978-0-429-42650-6 SP - 419 EP - 424 PB - Taylor & Francis CY - London ER - TY - THES A1 - Feucht, Thilo T1 - Additive Fertigung von Anschlusselementen im Stahlbau mit dem Wire Arc Additive Manufacturing N2 - In dieser Arbeit wird untersucht, wie stahlbauübliche Anschlusselemente mittels Wire Arc Additive Manufacturing (WAAM) gefertigt werden können. Die Motivation liegt darin, die heutzutage weiterhin übliche händische und zeitaufwendige Baugruppenfertigung durch einen vollautomatisierten Produktionsschritt zu ersetzen, indem die Anschlusselemente direkt auf Stahlträger additiv gefertigt werden. Die Grundlagen und Besonderheiten des WAAM werden dafür erläutert und beschrieben. Zur Ermöglichung eines WAAM-gerechten Konstruierens werden Lehrsätze im Sinne einer wissenschaftlichen Aussage formuliert. Mit dem präsentierten 8-schrittigen Optimierungsprozess werden die Strukturen der Anschlusselemente ermittelt, sodass das Material statisch optimal ausgenutzt wird und gleichzeitig eine schnelle und fehlerfreie Fertigung gelingt. Im Optimierungsprozess werden die numerische Topologieoptimerung sowie die numerische Traglastanalyse genutzt. Drei Anschlusselemente (Trägerhaken, Lasteinleitungssteife, Spannelement) werden bespielhaft optimiert. Im darauffolgenden Kapitel werden für jene Anschlusselemente geeignete Fertigungsstrategien erarbeitet und die Fertigung mit dem WAAM beschrieben. Die Tragfähigkeit der Anschlusselemente wird in zerstörenden Versuchen ermittelt und abschließend in einem Auswertungskapitel mit den numerischen Tragfähigkeiten verglichen. N2 - In this thesis it is investigated how common connection-elements in steel-construction can be manufactured by means of Wire Arc Additive Manufacturing (WAAM). The idea was to replace the manual and time-consuming assembly process, which is still common today, by a fully-automated manufacturing-step through additively manufacturing the connection elements directly onto the steel beams. The basics and particularities of WAAM are explained and described. To enable WAAM-compatible design, theorems as science-based statements are formulated. With the 8-step optimization process presented in this work, the structures of the connection-elements are determined. This ensures that the material is statically optimally utilized while a fast and error-free manufacturing process is guaranteed. Numerical topology-optimization and numerical ultimate-load analysis are used in the optimization process. For practical demonstration, three connection elements (beam hook, load-introduction stiffener, clamping element) are optimized. In a following chapter, suitable manufacturing strategies for these connection elements are outlined. The manufacturing process with the WAAM is described. The ultimate load-capacity of the connection elements is determined via destructive tests. In an evaluation chapter, the outcomes of these tests are compared with the numerical ultimate load-capacities. T2 - Additive Manufacturing of Connection Elements in Steel Construction by means of Wire Arc Additive Manufacturing UR - https://doi.org/10.26083/tuprints-00024363 Y1 - 2023 UR - https://doi.org/10.26083/tuprints-00024363 UR - http://nbn-resolving.de/urn/resolver.pl?urn:nbn:de:bvb:573-57507 PB - Technische Universität Darmstadt CY - Darmstadt ER -