EN 1993-1-1 gives stability design rules for columns, beams and beam–columns up to S460, whereas EN 1993-1-12 gives additional guidance for S500 up to S700. Recent studies show that high strength steel members may be designed using improved buckling curves, where the enhanced behaviour is usually attributed to the improved material properties but mainly due to the more favourable residual stress distribution. The behaviour of unrestrained beams in HSS has not been widely studied. At present in EN 1993-1-1, the design rules for lateral-torsional buckling of beams are not dependent on the steel grade, meaning that the code does not distinguish between beams in conventional strength steel or HSS. In pursuit of an answer to the mentioned shortcomings, the present research is based on the experimental programme covering 12 full-scale tests, residual stress measurements, advanced numerical models and analytical derivations. The experiments cover different steel grades up to S690, welded and hot-rolled sections, homogeneous and hybrid (flanges in HSS and web in mild steel), double and mono-symmetric sections as well as variations in the cross-section class. This paper provides an overview of the experimental programme, discusses the results for lateral-torsional buckling of beams, and presents an advanced numerical model that was calibrated to the experimental results including the measured residual stress distribution and geometrical properties of the members. The numerical model was explored to assess various assumptions for the member imperfections, and these are further compared with code recommendations.@en

EN 1993-1-1 gives stability design rules for columns, beams and beam–columns up to S460, whereas EN 1993-1-12 gives additional guidance for S500 up to S700. Recent studies show that high strength steel members may be designed using improved buckling curves, where the enhanced behaviour is usually attributed to the improved material properties but mainly due to the more favourable residual stress distribution. The behaviour of unrestrained beams in HSS has not been widely studied. At present in EN 1993-1-1, the design rules for lateral-torsional buckling of beams are not dependent on the steel grade, meaning that the code does not distinguish between beams in conventional strength steel or HSS. In pursuit of an answer to the mentioned shortcomings, the present research is based on the experimental programme covering 12 full-scale tests, residual stress measurements, advanced numerical models and analytical derivations. The experiments cover different steel grades up to S690, welded and hot-rolled sections, homogeneous and hybrid (flanges in HSS and web in mild steel), double and mono-symmetric sections as well as variations in the cross-section class. This paper provides an overview of the experimental programme, discusses the results for lateral-torsional buckling of beams, and presents an advanced numerical model that was calibrated to the experimental results including the measured residual stress distribution and geometrical properties of the members. The numerical model was explored to assess various assumptions for the member imperfections, and these are further compared with code recommendations.@en

Selected, extended paper from the SDSS 2019 special session ECCS/TC8 – Structural Stability. Cable-stayed columns offer several advantages among traditional solutions. Owing to the additional restraint given by the prestressed cables and cross-arms, they can provide enhanced buckling resistance in comparison to conventional columns. They are also aesthetically appealing, combining a strong architectural effect with a top-notch engineering solution. This paper presents a design approach for the stability design of prestressed cable-stayed columns. This method is based on the well-known Ayrton-Perry format, combining first- and second-order effects. The imperfection factors were calibrated on the basis of experimental results. This method is consistent with design rules for uniform columns in Eurocode 3 and is easy to apply.@en

Purpose: Additive manufacturing (AM) is a rapidly evolving manufacturing process, which refers to a set of technologies that add materials layer-by-layer to create functional components. AM technologies have received an enormous attention from both academia and industry, and they are being successfully used in various applications, such as rapid prototyping, tooling, direct manufacturing and repair, among others. AM does not necessarily imply building parts, as it also refers to innovation in materials, system and part designs, novel combination of properties and interplay between systems and materials. The most exciting features of AM are related to the development of radically new systems and materials that can be used in advanced products with the aim of reducing costs, manufacturing difficulties, weight, waste and energy consumption. It is essential to develop an advanced production system that assists the user through the process, from the computer-aided design model to functional components. The challenges faced in the research and development and operational phase of producing those parts include requiring the capacity to simulate and observe the building process and, more importantly, being able to introduce the production changes in a real-time fashion. This paper aims to review the role of robotics in various AM technologies to underline its importance, followed by an introduction of a novel and intelligent system for directed energy deposition (DED) technology. Design/methodology/approach: AM presents intrinsic advantages when compared to the conventional processes. Nevertheless, its industrial integration remains as a challenge due to equipment and process complexities. DED technologies are among the most sophisticated concepts that have the potential of transforming the current material processing practices. Findings: The objective of this paper is identifying the fundamental features of an intelligent DED platform, capable of handling the science and operational aspects of the advanced AM applications. Consequently, we introduce and discuss a novel robotic AM system, designed for processing metals and alloys such as aluminium alloys, high-strength steels, stainless steels, titanium alloys, magnesium alloys, nickel-based superalloys and other metallic alloys for various applications. A few demonstrators are presented and briefly discussed, to present the usefulness of the introduced system and underlying concept. The main design objective of the presented intelligent robotic AM system is to implement a design-and-produce strategy. This means that the system should allow the user to focus on the knowledge-based tasks, e.g. the tasks of designing the part, material selection, simulating the deposition process and anticipating the metallurgical properties of the final part, as the rest would be handled automatically. Research limitations/implications: This paper reviews a few AM technologies, where robotics is a central part of the process, such as vat photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, DED and sheet lamination. This paper aims to influence the development of robot-based AM systems for industrial applications such as part production, automotive, medical, aerospace and defence sectors. Originality/value: The presented intelligent system is an original development that is designed and built by the co-authors J. Norberto Pires, Amin S. Azar and Trayana Tankova.@en

Purpose: Additive manufacturing (AM) is a rapidly evolving manufacturing process, which refers to a set of technologies that add materials layer-by-layer to create functional components. AM technologies have received an enormous attention from both academia and industry, and they are being successfully used in various applications, such as rapid prototyping, tooling, direct manufacturing and repair, among others. AM does not necessarily imply building parts, as it also refers to innovation in materials, system and part designs, novel combination of properties and interplay between systems and materials. The most exciting features of AM are related to the development of radically new systems and materials that can be used in advanced products with the aim of reducing costs, manufacturing difficulties, weight, waste and energy consumption. It is essential to develop an advanced production system that assists the user through the process, from the computer-aided design model to functional components. The challenges faced in the research and development and operational phase of producing those parts include requiring the capacity to simulate and observe the building process and, more importantly, being able to introduce the production changes in a real-time fashion. This paper aims to review the role of robotics in various AM technologies to underline its importance, followed by an introduction of a novel and intelligent system for directed energy deposition (DED) technology. Design/methodology/approach: AM presents intrinsic advantages when compared to the conventional processes. Nevertheless, its industrial integration remains as a challenge due to equipment and process complexities. DED technologies are among the most sophisticated concepts that have the potential of transforming the current material processing practices. Findings: The objective of this paper is identifying the fundamental features of an intelligent DED platform, capable of handling the science and operational aspects of the advanced AM applications. Consequently, we introduce and discuss a novel robotic AM system, designed for processing metals and alloys such as aluminium alloys, high-strength steels, stainless steels, titanium alloys, magnesium alloys, nickel-based superalloys and other metallic alloys for various applications. A few demonstrators are presented and briefly discussed, to present the usefulness of the introduced system and underlying concept. The main design objective of the presented intelligent robotic AM system is to implement a design-and-produce strategy. This means that the system should allow the user to focus on the knowledge-based tasks, e.g. the tasks of designing the part, material selection, simulating the deposition process and anticipating the metallurgical properties of the final part, as the rest would be handled automatically. Research limitations/implications: This paper reviews a few AM technologies, where robotics is a central part of the process, such as vat photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, DED and sheet lamination. This paper aims to influence the development of robot-based AM systems for industrial applications such as part production, automotive, medical, aerospace and defence sectors. Originality/value: The presented intelligent system is an original development that is designed and built by the co-authors J. Norberto Pires, Amin S. Azar and Trayana Tankova.@en

Purpose: Additive manufacturing (AM) is a rapidly evolving manufacturing process, which refers to a set of technologies that add materials layer-by-layer to create functional components. AM technologies have received an enormous attention from both academia and industry, and they are being successfully used in various applications, such as rapid prototyping, tooling, direct manufacturing and repair, among others. AM does not necessarily imply building parts, as it also refers to innovation in materials, system and part designs, novel combination of properties and interplay between systems and materials. The most exciting features of AM are related to the development of radically new systems and materials that can be used in advanced products with the aim of reducing costs, manufacturing difficulties, weight, waste and energy consumption. It is essential to develop an advanced production system that assists the user through the process, from the computer-aided design model to functional components. The challenges faced in the research and development and operational phase of producing those parts include requiring the capacity to simulate and observe the building process and, more importantly, being able to introduce the production changes in a real-time fashion. This paper aims to review the role of robotics in various AM technologies to underline its importance, followed by an introduction of a novel and intelligent system for directed energy deposition (DED) technology. Design/methodology/approach: AM presents intrinsic advantages when compared to the conventional processes. Nevertheless, its industrial integration remains as a challenge due to equipment and process complexities. DED technologies are among the most sophisticated concepts that have the potential of transforming the current material processing practices. Findings: The objective of this paper is identifying the fundamental features of an intelligent DED platform, capable of handling the science and operational aspects of the advanced AM applications. Consequently, we introduce and discuss a novel robotic AM system, designed for processing metals and alloys such as aluminium alloys, high-strength steels, stainless steels, titanium alloys, magnesium alloys, nickel-based superalloys and other metallic alloys for various applications. A few demonstrators are presented and briefly discussed, to present the usefulness of the introduced system and underlying concept. The main design objective of the presented intelligent robotic AM system is to implement a design-and-produce strategy. This means that the system should allow the user to focus on the knowledge-based tasks, e.g. the tasks of designing the part, material selection, simulating the deposition process and anticipating the metallurgical properties of the final part, as the rest would be handled automatically. Research limitations/implications: This paper reviews a few AM technologies, where robotics is a central part of the process, such as vat photopolymerization, material jetting, binder jetting, material extrusion, powder bed fusion, DED and sheet lamination. This paper aims to influence the development of robot-based AM systems for industrial applications such as part production, automotive, medical, aerospace and defence sectors. Originality/value: The presented intelligent system is an original development that is designed and built by the co-authors J. Norberto Pires, Amin S. Azar and Trayana Tankova.@en

This paper presents an overview of the current design procedures for the buckling design of members, plates and curved panels. It highlights recent developments in these fields, namely methodologies for the evaluation of the buckling resistance of generic beam-columns with variable cross section, loading and boundary conditions, the evaluation of the reliability of the Winter curve in slender webs and the development of design guidance for curved panels. Finally, the incorporation of some of these developments in the current revision of Eurocode 3 is discussed.@en

Residual stresses have considerable effect on both the local and the member stability behaviour of steel structures. Previous studies have shown that the structural stability behaviour depends on both the distribution and the amplitude of the residual stresses. The residual stress distribution is affected by the cross-section geometry, the steel grade and the manufacturing process, e.g. flame cutting and the welding procedure. A realistic consideration of residual stresses is necessary for an efficient and safe design of steel structures. This article presents an experimental and numerical study on the influence of residual stresses on the stability behaviour of structural members, i.e. steel columns and beams considering a variety of cross-sectional slenderness, i.e. plastic, compact and slender cross-sections are taken into account. A novel residual stress model for welded I-shaped sections was developed and evaluated using test data. This model takes into account the main influencing parameters, i.e. the cross-sections geometry, the steel grade as well as manufacturing process with thermal cuts or non-thermal cuts of the steel plates. The novel residual stress model is then used to investigate the stability behaviour in terms of a numerical simulation study. The result of the study allows to propose an improvement of the buckling curve selection for welded high strength steel columns and beams.@en

This paper analyses the microstructural and mechanical properties of carbon steel coupons produced by CMT-WAAM. The strategy adopted in the fabrication of the test specimens using a robotised facility is explained. Then, the results of the mechanical characterization performed using as-built and machined samples, extracted in several directions (0°, 45°, 90°) relative to the material deposition trajectory, are analysed. The yield and ultimate tensile strengths were determined by performing tensile tests and the Young's modulus was determined using ultra-micro hardness measurements. A deep microstructural characterization was also performed by optical microscopy for establishing a direct relationship between the manufacturing procedures and the registered mechanical properties. The failure micro-mechanisms associated with the building orientation and the surface condition was also examined by scanning electron microscopy. It was found out that the additive manufactured material has isotropic tensile properties, which result from the formation of an annealed microstructure upon cooling from the successive CMT-WAAM thermal cycles. The machined specimens exhibit higher strength and ductility than the as-built ones. The fracture surfaces of both machined and as-built coupons showed ductile failure. The results of the uniaxial tensile tests indicate that the machined and as-built WAAM steel walls satisfy the requirements of a structural steel grade as specified by Eurocode 3.@en

This paper aims to assess the influence of geometrical imperfections and residual stresses on the reliability of the stability design rules for steel columns in Eurocode 3 considering a full probabilistic approach and further validate the new buckling curves in the scope of the ongoing revision of the Structural Eurocodes. A reliability assessment of major- and minor-axis flexural buckling of high-strength steel (HSS) welded I-section columns was performed, considering all basic variables as random, including the geometrical and material imperfections, in addition to the material properties of steel and the geometry of the cross-section. An advanced finite element model calibrated with experimental test results is used to perform a very large (290,126 simulations) parametric study covering the majority of practical geometries. Subsequently, Monte Carlo simulation is used to estimate the design values of the buckling resistance that correspond to the target probability of failure of the Eurocodes. Finally, these values are compared to the proposed buckling curves for HSS columns, showing good agreement and supporting their adoption in the revised EN 1993–1-1. It is also concluded that it is on the safe side to carry out a reliability assessment with deterministic reference values for structural imperfections.@en

The use of 3D printed stainless steel requires a deep knowledge of its mechanical properties. This paper presents material characterisation of 316LSi austenitic stainless-steel coupons manufactured by CMT-WAAM, considering different deposition directions. The specimens were tested according to ISO 6892-1, the fractures surfaces were examined by SEM for machined and as-built conditions. The material was subject to hardness test and deep microstructural analyses, to assess the anisotropy in material properties at the micro and macro scales, respectively. A thermal analysis performed by infrared thermography of the material deposition in CMT-WAAM was also performed to establish the influence of the temperature evolution (versus time and position) on the microstructural and mechanical properties of the deposited walls. Finally, a statistical assessment was carried out, including results available in the literature and a material model available in the literature was adjusted to the test results, enabling to conclude that it is possible of accurately reproducing the uniaxial stress-strain behaviour, therefore providing a necessary input for the design of steel structures with 3D printed stainless steel.@en

The lateral-torsional resistance of prismatic double-symmetric I-section beams is accurately predicted using a mechanically consistent Ayrton-Perry approach, combined with a calibrated generalized imperfection. The corresponding design formulation was recently adopted in the revised version of Eurocode 3. However, for prismatic mono-symmetric I-section beams, the General Case shall be used while for non-prismatic beams only the General Method is available. Both methods present a very large scatter and highly underestimate the lateral-torsional buckling resistance. This paper proposes an extension to the General Formulation for non-prismatic beams with arbitrary boundary conditions, partial lateral restraints, and arbitrary loading for mono-symmetric I-sections. Using an advanced numerical model calibrated with experimental test results, a large parametric study is undertaken, and its results are used to assess the available design methodologies and the proposed method. It is concluded that the General Formulation provides excellent safe-sided estimates of the LTB resistance, and it is confirmed the very poor performance of the General Case and the General Method.@en

The design of pin connections between steel members has been established for many years in design codes. However, recently, in the scope of the revision of Eurocode 3, Part 1–8 (EN 1993–1-8), questions were raised concerning the safety of the corresponding design verifications. This paper identifies two main aspects that require revision, namely: (i) the possibility to design a pin as a bolt in shear and (ii) the verification of the resistance of the pin itself. Based on a thorough literature review, experimental tests and a parametric study, a new proposal submitted to CEN as an amendment to the code, is presented to solve these two identified issues.@en

The component method for joint analysis relies on the formulation of stiffness and strength of individual parts to derive the global properties of the joint. One of these components is the web of an open I-section, or the face of a rectangular hollow section, hereby referred to as face plate. It is currently not codified despite its frequent occurrence in the engineering practice. Hereby, a new mechanical model is proposed to estimate the initial stiffness of the face plate component under out-of-plane loading, leading to closed-form analytical expressions. The model is validated against experimental test results and an extensive numerical parametric study, showing excellent agreement.@en