Additive manufacturing of a bridge in situ. Issue 2 (22nd April 2022)

• Record Type: Journal Article
• Authors: Feucht, Thilo; Waldschmitt, Benedikt; Lange, Jörg; Erven, Maren
• Is Part Of: Steel construction. Volume 15:Issue 2(2022)
• Page Start: 100
• Page End: 110
• Publication Date: 2022-04-22
• Subjects: additive manufacturing -- innovative structures -- steel bridge -- in situ manufacturing -- wire and arc additive manufacturing -- parametric robot programming; Welding and cutting -- Special structures; Schweißen und Schneiden -- Sonderkonstruktionen; Building, Iron and steel -- Design and construction -- Periodicals; Steel, Structural -- Periodicals; Iron and steel bridges -- Design and construction -- Periodicals; Structural steel industry -- Europe -- Periodicals; 721.044714205
• DOI: 10.1002/stco.202100045
• Languages: English
• ISSNs: 1867-0520

Abstract

Abstract: Nominated for Eurosteel 2021 Best Paper Award Additive manufacturing (AM) is playing an increasing role in the production of complex steel structures. Robot‐ or machine‐guided gas‐shielded metal arc welding (GMAW), known as wire and arc additive manufacturing (WAAM), is suitable for this purpose. A small footbridge was designed in shell form at TU Darmstadt. It was completely additively manufactured over a stream on site using a welding robot. The work called for cantilevered manufacturing without support structures, which poses special challenges in manufacturing. This paper describes selected aspects of this project: the preliminary strength studies, the manufacturing strategy to ensure homogeneous manufacturing and the findings from on‐site manufacturing. In addition, investigations were carried out which led to a notable increase in the deposition rate with the right choice of gas and wire.