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.

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.

Residual stresses have major influence on the stability of steel members. It is well-known that, due to the differences in manufacturing procedures, the residual stresses for welded and hot – rolled members are rather different. In the same way, despite several studies on residual stresses distribution and magnitude for hot-rolled members were already done, for prismatic and tapered welded I section steel members the investigation is still very scarce. In the current work, an experimental programme on the buckling resistance of tapered members, with different tapering ratios and section heights, was conducted and residual stress measurements were carried out using the sectioning method. Numerical simulations of the heat input during welding were also performed in order to predict the residual stress fields. A statistical analysis of the residual stresses distribution for welded I section members was performed, using the experimental and numerical results, as well as literature data. Systematized information on residual stresses distribution and magnitude was generated and some guidelines for the statistical characterization of residual stresses in welded members were proposed.