Production of 3D printed steel nodes structures

An insight into the procedure for manufacturing node structures in steel construction using Wire and Arc Additive Manufacturing (WAAM) and the numerical and experimental investigation of the node structures is given. Based on the geometric complexity of intersecting steel profile bars, essential points in the simulation-based determination of node structures are described. Depending on the load cases, different structures can be found via topology optimization. For the production of the node structure by wire and arc additive manufacturing, the numerically found geometry must be adapted and path planning variants have to be developed and evaluated. The influence of process parameters on warpage, near net shape and mechanical properties of the components is also examined. A simplified thermal and mechanical analysis of the manufacturing process is carried out for the prognosis of the stress and deformation states of the node. Furthermore, a method for in-process quality assurance is presented, which recognizes process irregularities on the basis of sensor data and evaluates their influence on the mechanical properties of the component, whereby measures for error correction can be taken early in the process and costs through rejects can be reduced.