Abstract
This paper presents a comprehensive experimental investigation into the double-lap shear behavior of 3D printed austenitic stainless steel bolted connections, manufactured using wire arc additive manufacturing (WAAM) and ER316L feedstock wire. A total of 43 double shear bolted connections were tested, considering variations in end and edge distances, surface conditions (milled and as-built) and test orientations. Details regarding the manufacturing process, geometric measurements using 3D laser scanning, and tensile connection tests are provided. The key test results, encompassing failure modes, load-deformation curves, and resistances with and without consideration of bolt hole deformation, are reported and discussed. The test results were compared with resistances predicted by existing design rules documented in current American Specifications (AISC 360–22, AISC 370–21 and ASCE 8–22) and the Active Shear Plane-based Method from relevant literature, originally calibrated for conventionally fabricated steel lap-shear connections, in order to to assess their applicability for WAAM austenitic stainless steel connections. The comparison results indicated that the resistance predictions by the aforementioned American Specifications are generally conservative for WAAM 316 L austenitic stainless steel double shear bolted connections when considering bolt hole deformation, with AISC 360–22 being the most accurate. When bolt hole deformation is not a design concern, the Active Shear Plane-based Method was shown to provide the most accurate resistance predictions.
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