Steel Design Research Articles

Intelligent design of steel–concrete composite beams based on deep reinforcement learning

In this work, an automated member design method is proposed based on deep reinforcement learning (DRL). Using steel–concrete composite beam design as a case study, the design procedure is conceptualized as a sequential optimization process and modeled as a Markov Decision Process (MDP). A design agent equipped with two deep neural networks, is trained using the proximal policy optimization (PPO) method to complete the complex design task of steel–concrete composite beams, adhering to the Chinese standard for design of steel structures GB50017-2017 provisions. The structural provisions are integrated into a simulated design environment, which can respond to the agent’s actions. A universal reward shaping function is introduced to guide the agent towards success and minimize material cost. The design quality and generation performance of trained PPO agent are compared with those of the Differential Evolution (DE) in 100 random training cases, 100 random testing cases, and 95 real-world engineering cases, demonstrating significant promise and reduced time consumption for automated steel–concrete composite beam design. An approach combining PPO with DE is proposed to enhance the robustness and reliability of the original agent. Finally, a brief discussion is conducted on the essence and prospects of the proposed method.

Active learning strategies for the design of sustainable alloys.

Active learning comprises machine learning-based approaches that integrate surrogate model inference, exploitation and exploration strategies with active experimental feedback into a closed-loop framework. This approach aims at describing and predicting specific material properties, without requiring lengthy, expensive or repetitive experiments. Recently, active learning has shown potential as an approach for the design of sustainable materials, such as scrap-compatible alloys, and for enhancing the longevity of metallic materials. However, in-depth investigations into suited best-practice strategies of active learning for sustainable materials science are still scarce. This study aims to present and discuss active learning strategies for developing and improving sustainable alloys, addressing single-objective and multi-objective learning and modelling scenarios. As model cases, we discuss active learning strategies for optimizing Invar and magnetic alloys, representing single-objective scenarios, and more general steel design approaches, exemplifying multi-objective optimization. We discuss the significance of finding the right balance between exploitation and exploration strategies in active learning and suggest strategies to reduce the number of iterations across diverse scenarios. This kind of research aims to find metrics for a more effective application of active learning and is used here to advance the field of sustainable alloy design.This article is part of the discussion meeting issue 'Sustainable metals: science and systems'.

Thermodynamic calculation-assisted design of 500 MPa high performance steel by machine learning

In order to rationally design Q500 low-alloy wind power steel with stable microstructure and properties within a large cooling rate range, this study proposed a design system that utilizes thermodynamic database, machine learning (ML), and the multi-objective genetic optimization algorithm (MOGA). Thermodynamic calculation has been used to obtain a large amount of data on phase fractions and mechanical properties for various chemical composition at different cooling rates. By comparing the predictive capabilities of different ML models, the deep neural network (DNN) and MOGA were combined to design Q500 wind power steel. Subsequently, three groups of designed chemical compositions were appropriately selected for verification. The results indicate that the yield strength of the experimental steel was over 500 MPa, and the maximum error in microstructure and mechanical property prediction was 5.0%. The prediction results demonstrated the rationality of the composition design framework. Meanwhile, the method of combining the material database and ML proposed in this study can also be applied to the design of other low-alloy steels.

Seismic design of steel moment‐resisting knee‐braced frame system by failure mode control

AbstractThis paper presents the seismic design of a steel moment‐resisting knee‐braced frame (MKF) using the theory of plastic mechanism control (TPMC) within the capacity‐based design framework. The MKF is an alternative system to MRFs, wherein knee elements are utilized to provide rigid connections and enhance lateral stiffness. Capacity‐based design, the predominant approach in current seismic provisions, relies on two key principles: (1) selecting specific structural components as fuses with sufficient ductility to dissipate seismic energy, and (2) ensuring non‐fuse elements can resist the maximum probable reactions from these fuses. The ultimate goal is to achieve a global mechanism where yielding occurs in all structural fuses and at the base of first‐story columns. However, existing seismic design provisions often struggle to fully satisfy the second principle due to the lack of a method for controlling failure modes. TPMC addresses this challenge by ensuring compliance with the second principle, grounding its approach in the kinematic method and the mechanism equilibrium curve within the rigid‐plastic analysis framework. By considering all potential story‐based undesirable mechanisms and calculating the required plastic moment of columns up to a target design displacement, TPMC ensures adherence to the second principle of the capacity‐based design approach, leading to the achievement of a global collapse mechanism. In this paper, an iterative method is proposed for designing beams and knee elements by considering plastic hinges at both ends of the beams, followed by a TPMC‐based methodology for designing columns to ensure a global mechanism. A parametric analysis of a single‐story single‐span MKF explores the effects of knee element geometry ( and ) on component demands. The results indicate that optimal parameter ranges of and can minimize the demands for MKF components. Practical design examples are illustrated using three steel MKFs, each consisting of four, seven, and ten stories with five spans. Pushover analysis and nonlinear dynamic analyses were performed to demonstrate the effectiveness of the proposed design procedure in ensuring the attainment of a global mechanism and excellent seismic performance under real ground motions.

A new plastic global analysis approach for the fire design of steel and stainless steel structures

The new generation of structural codes for stainless steel allow carrying out global plastic analyses on certain types of stainless steel structures with plastic cross-sections at room temperature if the joints conforming the structure are classified as full-strength joints, a capability that has been long recognised for carbon steel structures. However, the requirements for the fire design of carbon and stainless steel structures in current and upcoming European design standards are still primarily based on the resistance of individual members, disregarding the redistribution of internal forces and strain hardening effects. Recent studies have proven that carbon and stainless steel frames with plastic cross-sections and full-strength joints are capable of redistributing internal forces at elevated temperatures, and failed describing global plastic collapse mechanisms under fire situation, suggesting that system effects are also relevant at elevated temperatures and could be taken into account for more efficient designs. On this basis, this paper develops an extensive numerical study focused on carbon and stainless steel frames under fire situation, and proposes a new methodology based on plastic global analysis to estimate the resistance of such structures under fire situation accounting for their redistribution capacity, improving the accuracy of the predicted fire time resistances significantly for the two materials.

Hydrogen Embrittlement Behavior of API X70 Linepipe Steel under Ex Situ and In Situ Hydrogen Charging.

This study investigates the hydrogen embrittlement behavior of API X70 linepipe steel. The microstructure was primarily composed of a dislocation-rich bainitic microstructure and polygonal ferrite. Slow strain-rate tests (SSRTs) were performed under both ex situ and in situ electrochemical hydrogen charging conditions to examine the difference between hydrogen diffusion and trapping behaviors. The ex situ SSRTs showed almost the same tensile properties as air and a limited brittle fracture confined to near the surface. In contrast, the in situ SSRTs showed an abrupt failure after the maximum tensile load, leading to a brittle fracture across the entire fracture surface with stress-oriented hydrogen-induced cracking (SOHIC). The crack trace analysis results indicated that SOHIC propagation paths were influenced by localized hydrogen accumulation due to high-stress fields. As a result, the dominant hydrogen embrittlement mechanisms, such as hydrogen-enhanced localized plasticity (HELP) and hydrogen-enhanced decohesion (HEDE), changed. These findings provide critical insights into the microstructural factors affecting hydrogen embrittlement, which are essential for the design of hydrogen-resistant steels in hydrogen infrastructure applications.

Seismic Local Buckling Limits for Hollow Structural Section and Built-Up Box Columns

Recently completed research on seismic local buckling limits for steel hollow structural section (HSS) and built-up box columns is featured. These National Center for Research on Earthquake Engineering (NCREE) studies are led by Dr. Chung-Che Chou and Dr. Tung-Yu Wu in the Department of Civil Engineering at National Taiwan University (NTU). Dr. Chou also serves as the NCREE Director. Dr. Chou’s research has focused on seismic testing, analysis, and design for steel and post-tensioned self-centering structures. Some recent work includes studies on hybrid simulation of a full-scale steel moment frame, a post-tensioned self-centering brace, novel prediction models for early earthquake warnings, and earthquake reconnaissance work in eastern Taiwan. Dr. Chou’s numerous accolades include the Awards for Excellent Research and Technology Transfers for his leadership on a research team developing a sandwiched buckling-restrained brace and a self-centering brace. Dr. Wu’s research interests include collapse behavior of cold-formed HSS columns under seismic loading, subwavelength seismic metamaterial structures, crack growth in railway crossings under high wheel-rail impacts, and seismic resilience of steel buildings. In addition to multiple scholarships and fellowships, Dr. Wu’s honors include the Raymond C. Reese Research Prize, awarded by the American Society of Civil Engineers (ASCE) for papers representing notable achievements in research with impact on design. The National Science and Technology Council is supporting this research on seismic local buckling limits for HSS and built-up box columns. Selected highlights from both projects are presented, along with a preview of future research tasks.

Inverse design of high-strength medium-Mn steel using a machine learning-aided genetic algorithm approach

To develop medium-Mn steels with an ultimate tensile strength (UTS) exceeding 2 GPa and excellent ductility, we created a highly accurate UTS prediction machine learning (ML) model using a boosted decision tree model and 1520 dataset of tensile properties of medium-Mn steels with micro-alloying elements. We also optimized the hyper-parameters of a genetic algorithm (GA) using the Shannon diversity index to enhance search efficiency while retaining diversity. In a high-dimensional search space with millions of potential combinations, the ML-GA approach efficiently identified diverse chemical compositions and austenitizing conditions to achieve UTSs above 2 GPa. The k-means clustering method then grouped them into five distinct specimens based on similarities. These five specimens, fabricated using inversly designed chemical compositions and austenitizing temperatures, successfully exhibited UTSs exceeding 2 GPa and greater ductility compared to hot-stamped C steels. These excellent tensile properties were attributed to grain refinement resulting from the low austenitizing temperature and the pinning effect of micro-alloying element carbides, such as TiC and VC.

Dynamic fracture toughness and crack propagation mechanism of a heterogeneous heterostructured material under combined strengthening mechanisms

Developing fracture-resistant high-strength steels is an attractive prospect for various structural applications. In this work, a combination of carburizing heat treatment (CHT) and shot peening (SP) was used to develop combined strengthening (CS) mechanisms and to improve the mechanical strength and dynamic fracture toughness of 18CrNiMo7-6 alloy steel. Standard tensile tests and split Hopkinson pressure bar tests were conducted to investigate the strength and dynamic fracture toughness of the 18CrNiMo7-6 alloy steel. The crack initiation and propagation of samples were studied using scanning electron microscopy and transmission electron microscopy. Microstructure characterization and molecular dynamic simulations indicated that the excellent dynamic fracture toughness of the CS samples could be attributed to the grain refinement after strengthening and the formation of numerous slip bands at the crack tips, reducing the stress concentration at the crack tips. The Cr23C6 precipitates have a positive effect on the strength improvement of 18CrNiMo7-6 alloy steel. The results showed that this research can be used to guide the design of steels with high-strength and high-dynamic fracture toughness.

Column-to-beam flexural strength ratio for rigorous strong-column–weak-beam design for steel–concrete composite frames

This study addresses the limited research and unclear principles surrounding the strong-column–weak-beam (S-C–W-B) criterion in steel–concrete composite frames, a critical aspect of structural engineering. Despite its widespread application in steel frames, the S-C–W-B criterion's adaptation to steel-concrete composite frames remains underexplored. The research aims to clarify and establish consistent guidelines for preventing column hinge formation at the joint, a key concern in S-C–W-B design. Beginning by analysing the definitions of ultimate flexural strength and flexural yielding strength of a section, essential components of the S-C–W-B criterion, the minimum column-to-beam flexural strength ratio (ηc, min) required for a robust S-C–W-B design was deduced. The methodology involves a novel parametric analysis using a fibre beam–column model. This model is used to derive a closed-form equation for ηc, min, which was then verified through time-history analysis using the finite-element software MSC.Marc. The findings indicate that the established ηc, min provides a stringent, nonetheless, reliable criterion for S-C–W-B design in steel-concrete composite frames. This research not only bridges a significant gap in existing structural engineering knowledge but also proposes a practical approach for safer and more efficient design in real-world applications.

Aerodynamic Performance‐Based Design for Steel Bridges and Embodied Carbon Awareness

AbstractConnecting infrastructures such as steel bridges are important for sustainable and economic development of society. Understanding the risks to these infrastructures associated with wind is crucial to ensure their resilience, particularly with the evident threat of climate change. The authors will discuss the benefits of early‐stage consulting in delivering climate aware performance‐based design for steel bridges.A holistic approach comprising bridge monitoring, aerodynamic consultation coupled with wind tunnel testing and numerical simulations enables us to understand the structural response of bridges, from an aerodynamic perspective. By combining this knowledge with a local climate model, the bridge response to current and future expected wind conditions, can be predicted and assessed.The outcomes of such an approach enable us to refine design wind loads optimizing material usage and ensuring safe and cost‐effective construction processes, thereby reducing embodied carbon.

High strength steel unlipped channel sections subjected to ETF loading: Laboratory testing, numerical simulations and web crippling design

This paper presents web crippling and structural design of high strength steel unlipped channel sections under end-two-flange (ETF) loading based on experimental and finite element investigations. The experimental programme was composed of six grade S690 and four grade S960 test specimens, and the corresponding test set-up, procedures and results were reported in detail. The web crippling test results were used in the numerical modelling programme to validate the developed FE models, which were then adopted to perform parametric studies to enlarge parameter ranges of the bearing length, web slenderness and inside bend radius. Given that codified design rules for S690 and S960 high strength steel unlipped channel sections undergoing web crippling are absent, the corresponding normal strength steel design provisions, as stipulated in the European code EN 1993-1-3 and American specification AISI S100, were evaluated for their suitability to high strength steel unlipped channel sections. It is shown that the ultimate strength of high strength steel unlipped channel sections nonlinearly increases with increasing bearing length but with decreasing web slenderness and inside bend radius. The design methods of current EN 1993-1-3 and AISI S100 provide inaccurate and scattered resistance predictions for high strength steel unlipped channel sections. Finally, a modified AISI S100 design method and a slenderness-based design method were proposed, which can outperform the codified design methods.

Historical evolution of structural optimization techniques for steel skeletal structures including industrial design applications

This study covers the review of algorithms developed for the optimum design of steel skeletal structures from the first article published in 1960 until to date. The paper initially describes the mathematical formulation of a simple truss structural design problem. The early optimum design algorithms that were based on mathematical programming techniques where the design variables are assumed to be continuous are reviewed. The optimum design of steel framed structures necessitates the selection of steel profiles from the standard list of discrete steel sections and requires the satisfaction of design code provisions. Both mathematical programming and optimality criteria techniques need more capability to produce solution to this type of optimum design problems. Soft computing techniques emerged recently provide solution directly without needing any approximation. These techniques are classified and reviewed and their use in obtaining the optimum solution of actual industrial steel design applications is given.

Numerical modelling and design of cold-formed steel battens subject to pull-out failures under bushfire conditions

Thin and high strength cold-formed steel (CFS) battens and claddings serve as non-combustible elements in roof and wall cladding systems, aligning with the recommendations of Australian bushfire standards. However, they are susceptible to significant damage from heat and strong winds experienced during bushfire events, particularly in the form of batten pull-out failures. Such failures may occur at the screw connections between cladding and battens, or battens and trusses/rafters. However, pull-out failures often occur in the thinner CFS battens, when the screw fastener pulls out of the batten’s top flange, leading to the loss of entire cladding and compromising the integrity of the building envelope. This study used finite element modelling of a range of CFS batten configurations to investigate their pull-out failures under combined wind action and bushfire conditions. Finite element models were developed to simulate the pull-out failures at elevated temperatures, validated using experimental results and used in a parametric study to investigate the effects of relevant parameters. Using the results, this study has proposed suitable design equations for predicting the pull-out capacities of CFS battens at elevated temperatures. Engineers can use them to design bushfire safe CFS cladding systems.

Influence of submerged arc welding process parameters and metallurgical behaviour in a thick carbon steel section for boiler application

AbstractThe aim of the research is to investigate the weldability of thick sections of carbon steel using submerged arc welding with varying process parameters. The experimental design for joining thick carbon steel involves manipulating input weld process parameters such as current (A), voltage (V), weld speed (mm/h), and weld electrode diameter (mm). The quality of the weld material is assessed based on transformations in microstructure, weld hardness measured by Brinell hardness number, and tensile strength (MPa). It is crucial to note that the grain structure and metallurgical behavior of other hard materials may differ significantly. The presence of carbon in the ferrite phase has led to the formation of bainite, martensite, and composites of martensite and austenite within the weld zone, as confirmed by high‐resolution microscopy. The weldment‘s hardness has increased from 242.5 HV 30 in the base metal to 316.4 HV 30 in the weldment due to metallurgical alterations in the microstructure. Weld energy input emerges as the primary factor influencing weld quality. With increasing weld current and voltage, there is a corresponding increase in the joined metal, resulting in improved characteristics in the weld structure, particularly at maximal energy input and welding speed. In the context of boiler applications, understanding the weldability of thick carbon steel sections is paramount for ensuring structural integrity and longevity under high‐temperature and high‐pressure conditions. The optimized welding parameters identified in this study can contribute to enhancing the reliability and performance of boilers, thereby promoting safety and efficiency in industrial settings.

Effects of Partially Replacing Mo with Nb on the Microstructure and Properties of High-Strength Low-Alloy Steel during Reverse Austenization

This study investigated the effects of partially replacing expensive Mo with cheaper Nb on the microstructure and properties of high-strength low-alloy (HSLA) steel during reverse austenisation. The mechanical properties of the steel in the hot-rolled state were lower with a partial replacement of Mo by Nb. However, after pre-tempering and reheating and quenching, the strength increased greatly while the ductility and toughness did not decrease much. Thus, the negative effects of replacing Mo with Nb were mostly alleviated, and a good balance between strength, ductility and toughness was achieved. After heat treatment, the mass percentage of precipitates increased substantially, which helped to pin grain boundaries during austenisation. The percent of high-angle grain boundaries greatly increased while the average effective grain size decreased, which improved grain refinement. The results showed that combining a partial replacement of Mo by Nb with heat treatment allows the microstructure and mechanical properties of HSLA steel to be effectively controlled while improving the balance between cost and performance. These findings provide valuable insights into the preparation and design of steels with similar microstructures.

Post-fire structural material behaviour of high- and ultra-high-strength steels – Experimental study and aids for assessment for further use and potential reuse after fires

A thorough understanding and realistic modelling of the essential post-fire material behaviour is crucial for a safe assessment of the residual structural performance of steel components and the reliable further usage of steel structures after fires. This paper presents a comprehensive experimental study of the constitutive material behaviour after heating-cooling cycles of two quenched and tempered high-strength steels (S690QL, S960QL) as well as two thermomechanically rolled steels (S960M, S1100M). The results are compared to both the behaviour of grade S355J2+N mild steels and a comprehensive database of existing post-fire tests. Except for high- and ultra-high-strength steels, which are exposed to very high temperatures above the A1-phase-transformation-temperature during fires, the assumption of reversibility of the mechanical properties for structural designs of steel structures has been confirmed. At high and very high steel temperatures, the microstructure changes and the strength properties after fire are significantly lower than those of virgin high-strength steel specimens. The study thus provides the basis for reliable structural designs and future normative guidance of the post-fire structural steel designs.

New insights for composition design: A novel synergistic corrosion-resistant effect of Fe–Mn–Al–Cr–Si–Mo–C lightweight steel in 3.5 wt% NaCl solution

Nowadays, a good corrosion resistance of lightweight steel is demanded for its application. However, due to the high contents of Mn and C, which are always corrosion-susceptible elements in steels, the conventional lightweight steel is not desirable for this mission. Although Cr is widely believed to be a common alloying element to improve the corrosion resistance of most steels, it is considered to be ineligible using in the lightweight steel due to the relatively high content of C. This is because the trade-off between corrosion resistance and mechanical properties by alloying Cr. In recent years, the rapid developments of additive and coating manufacturing have provided new possibilities for both the Cr alloying and microstructural modulation to improve corrosion resistance of lightweight steel. In this case, to design a certain chemical composition using in additive and coating manufacturing, it is interesting to clarify the effects of Cr alloying on the corrosion resistance of lightweight steel. To reveal it, in the present work, the Fe–Mn–Al–Cr–Si–Mo–C lightweight steel alloyed with Cr contents of 4 wt%, 8 wt% and 12 wt% are prepared. The corrosion resistances and mechanisms of Cr-alloyed lightweight steels in 3.5 wt% NaCl solution are investigated by electrochemical and immersion tests. The present work may provide new insights for the composition design of lightweight steel, especially for the directions of additive and coating manufacturing.

DSM-Based failure load prediction of CFS pin-ended singly symmetric columns buckling in flexural-torsional modes

Recently, the authors investigated the post-buckling behaviour, strength and Direct Strength Method (DSM) design of cold-formed steel (CFS) fixed-ended singly symmetric columns buckling in major-axis flexural-torsional modes (FMT), some of which were shown to experience interaction with minor-axis flexural (Fm) buckling − FMT-Fm (global-global) interaction. The main fruit of this investigation was the development of an efficient DSM-based design approach capable of predicting the failure loads of such columns, regardless of their failure mode nature (pure FMT or FMT-Fm interactive). This work extends the scope of the above study to singly symmetric columns with three types of pin-ended support conditions, all fixed with respect to torsion and having warping fully prevented. Columns with seven cross-section shapes are considered, having their wall dimensions, lengths and yield stresses selected to ensure covering wide FMT slenderness ranges and various ratios between the Fm and FMT buckling loads. Following an investigation on the elastic and elastic-plastic post-buckling behaviours of the selected pin-ended columns, paying attention to the possible occurrence of FMT-Fm interaction, parametric studies are carried out to gather extensive pin-ended column failure load data, including some potentially associated with FMT-Fm interactive collapses. Then, the assembled numerical failure loads are used to show that (i) the available DSM-based strength curves are only able to predict adequately part of them and, thus, (ii) novel DSM-based design curves are needed to estimate the failure loads of the remaining pin-ended singly symmetric columns buckling in FMT modes. After developing such curves and assessing their merits (safety and reliability), it is concluded that different DSM-based design curves/approaches must be employed for columns with each type of pin-ended support conditions.

Die steel design for additive manufacturing

A novel printable die steel was computationally designed and experiemtnally validated for selective laser melting (SLM), utilizing the advantages of the rapid solidification processes. During gas atomization, nanoscale TiN particles are intended to be insitu precipitated at 1790°C, nucleating δ-ferritic grains. Additionally, the chemical composition is adjusted to stabilize a complete δ-ferritic solidification via Scheil modeling to enhance the printability of the die steel. This work further introduces the concept of the matrix die steels aiming to dissolve solidification and primary carbides during solutionizing at a targeted temperature of 1100°C. Thus, the C-content is reduced to 1.4 mol.-% (0.3 wt.-%) compared to the benchmark H13 die steel with which contains 1.85 mol.-% (0.4 wt.-%). Even though a lower C-content is used, optimizing M2C driving force during tempering enables the die steel to achieve a peak hardness of 536 HV is achieved. Lastly, a superior thermal conductivity of 40 W m-1 K-1 is predicted at 450°C for the BCC matrix of the printable matrix die steel. The material design is based on thermo-chemical models interfaced with thermodynamic calculations as implemented in the Calculated Phase Diagram (CALPHAD) method.