An experimental approach on the load‐bearing capacity of thin steel sheets reinforced using WAAM

Abstract

Wire Arc Additive Manufacturing (WAAM) is emerging as a promising solution for reinforcing thin‐sheet metal in façade construction. Against the backdrop of climate‐neutral industry goals and increasing automation needs in the construction sector, this paper presents an experimental investigation into the structural performance of WAAM‐reinforced sheet steel elements. The study focuses on physical tests of DC01 steel sheets with a thickness of 1.0 mm, reinforced on one side by two parallel ribs of either 6 or 10 welded layers with a thickness of 2.0 mm. Full‐scale specimens measuring 2200×400 mm were subjected to modified six‐point bending tests, to replicate façade‐relevant wind load scenarios. The experiments revealed a distinct correlation between reinforcement height and loadbearing capacity. Specimens with 10‐layer ribs exhibited higher resistance and delayed onset of plastic deformation compared to those with 6‐layer ribs. However, the increased build‐up height also reduced the arching effects caused by welding induced curvature. This paper presents the results of full‐scale load bearing tests of WAAM reinforced thin steel sheets for the first time, comparing the interaction of welded layers, welding induced curvature and load bearing capacity in order to establish a foundation for further design approaches aimed at sustainable and lightweight façade solutions.