Abstract

This research aims at exploring the potential benefits of additive manufacturing of corrugated web steel beam structural systems. Various three-dimensional models of corrugated web beams were created, manufactured, then analyzed by the finite element method. Four prototypes were manufactured using the traditional welding method, one regular, and three are corrugated web beams. Three other prototypes of corrugated web beams, similar to the previously traditionally manufactured, were created using additive manufacturing. Experimental tests were conducted on these prototypes. Both the finite element analysis and the experimental study showed that the additively manufactured beams having higher load carrying capacity when compared to traditionally manufactured ones. Also, the additively manufactured corrugated web beams performed very closely to the finite element analysis showing a high level of certainty making it possible to reduce the safety factors thus reducing the total costs. The results show that additive manufacturing technology can effectively be employed for creating structural systems without limitations and without causing any errors in the manufacturing process.

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