Predicted Failure Loads Research Articles

Additively-manufactured lattice-grid sandwich cylinders and elastoplastic multi-failure analyses

Aluminum alloy lattice-grid sandwich cylinders, comprising a symmetric pyramidal truss core and open grid face-sheets, are additively manufactured using the selective laser melting method. The compression behaviors of these sandwich cylinders are investigated. Failure is controlled by three competing mechanisms: global buckling, core shear instability and grid buckling, with the active failure mode determined by the cylinder geometry and the material yield stress. Failure criteria are defined in terms of the effective elastoplastic properties of the grid-skins and core, which agree well with the measured and simulated failure responses, and are applied to generate multi-failure maps with cylinder geometrical parameters as axes. The maps help with failure load prediction and design optimization. For these cylinders, grid buckling is proposed as the dominant failure mode.

Geometric analysis and local buckling behavior of wire arc additively manufactured ER110S cruciform section stub columns

The recent prominence and potential of wire arc additive manufacturing (WAAM) in the civil engineering industry have gained significant attention due to its ability to produce complex geometric shapes in a cost-effective and flexible manner. This paper presents the geometric analysis and local buckling behavior of WAAM ER110S cruciform section stub columns. A total of eight specimens with a broad range of width-to-thickness ratios were manufactured. 3D laser-scanning was conducted to capture the geometric characteristics of all the WAAM ER110S cruciform section stub column specimens. Material testing with coupons cut from various orientations of WAAM ER110S plates was performed and this is followed by the stub column testing where digital image correlation (DIC) was employed to monitor the full-field deformations of the specimens. The obtained test data were then employed to assess the applicability of current design rules specified in European, American and Australian standards to WAAM ER110S cruciform section stub columns. The assessment results revealed that (i) the current Class 3 slenderness limits (i.e. slender/non-slender slenderness limits) can be safely used for the classification of outstand plate elements of cruciform sections in compression and (ii) all the three specifications can lead to safe though marginally scattered failure load predictions of WAAM ER110S cruciform section stub columns.

Shear performance of GFRP reinforced UHPC short beams

This paper investigated experimentally the shear performance of ultra-high-performance concrete (UHPC) deep beams reinforced longitudinally with glass fiber reinforced polymer (GFRP) bars without web reinforcements. Ten beams were cast, in which seven were longitudinally reinforced with GFRP bars, while the remaining three were reinforced with steel bars for comparison. All beams had similar lengths and widths of 2000 mm and 150 mm, respectively, while the depths varied. The test parameters included the effective depth (d), shear span-to-depth ratio (a/d), number of longitudinal bars, and longitudinal reinforcement ratio (ρ). All the GFRP reinforced beams had higher shear capacities and lower post cracking stiffness than their steel counterparts. The experimental results show that varying the test parameters have a significant impact on the shear capacity of the beams. For instance, decreasing the a/d ratio for the GFRP reinforced beams from 1.8 to 1.5 and from 1.8 to 1.1 increased the load carrying capacity by 33 % and 95 %, respectively. The experimental results for the shear capacity were compared against the predictions obtained using the strut and tie method as per the ACI-318–19 and CSA-S806-12 codes. The failure load predictions by the ACI and CSA code showed the same trends as those shown in the experimental results. Moreover, both codes were conservative in predicting the shear capacities.

Failure mode and load prediction of steel bridge girders through 3D laser scanning and machine learning methods

AbstractCorrosion poses a significant threat to the longevity of steel bridges, impacting overall structural integrity. To effectively assess the structural condition of corroded steel bridges, conventional methods rely on visual inspections or single point measurements. To enhance and modernize this approach, this study introduces a novel framework integrating laser scanning data, computational models, and convolutional neural networks (CNNs). The CNN models are trained on a data set consisting of more than 1400 artificial corrosion scenarios generated by parameterizing real scan data from naturally corroded girders. This innovative method predicts the residual capacity and failure mode of corroded beam ends, achieving a low error rate of up to 3.3%. Unlike established evaluation procedures, the proposed evaluation framework directly utilizes post‐processed laser scanner output, eliminating the need for feature extraction and calculations.

DSM design of cold-formed steel fixed-ended lipped channel columns undergoing distortional-global interaction

This work reports a numerical investigation dealing with the post-buckling behaviour, strength, and Direct Strength Method (DSM) design of cold-formed steel fixed-ended lipped channel columns experiencing coupling between distortional and global (flexural-torsional) buckling − distortional-global (D–G) interaction. Various cross-section dimensions and lengths are considered, to ensure that the columns selected undergo different levels and types (“true”, “secondary-bifurcation distortional” or “secondary-bifurcation global”) of D–G interaction. The results presented and discussed, determined by means of Abaqus shell finite element geometrically and materially non-linear analyses, consist of elastic and elastic-plastic post-buckling equilibrium paths, failure loads and collapse modes. The steel material behaviour is deemed elastic-perfectly plastic and several yield stresses are considered, thus making it possible to cover a wide column D–G slenderness range. Particular attention is devoted to identifying the most detrimental initial geometrical imperfection shapes, in the sense that they lead to the lowest column failure loads. The numerical failure load data gathered are subsequently used to assess the merits of the available DSM-based design approaches developed to handle cold-formed steel columns undergoing D–G interaction. Since these design approaches are shown to be either inefficient and/or improvable, the above failure load data are also used to propose modifications/improvements aimed at achieving an efficient failure load prediction in the specific context of fixed-ended lipped channel columns. The success of this endeavour provides encouragement to the authors in their search for a safe, accurate and reliable DSM-based design approach capable of handling cold-formed steel columns with arbitrary cross-section shapes and/or end support conditions that fail in D–G interactive modes.

Post-fire behavior and residual resistances of S890 ultra-high strength steel circular hollow sections under combined compression and bending

This paper presents experimental and numerical investigations into the post-fire local buckling behavior and residual resistances of S890 ultra-high strength steel (UHSS) circular hollow section (CHS) under combined compression and bending. The physical testing was firstly conducted and encompassed heating, soaking and cooling of specimens, as well as post-fire tensile coupon tests, measurements of initial local geometric imperfections and eccentrically loaded stub column tests. Then, finite element models were developed and validated with reference to the experimental observations and then adopted for parametric analyses to derive additional numerical data, considering various cross-section dimensions and loading combinations. As a result of the lack of design provisions for ultra-high strength steel structures after exposure to elevated temperatures, the applicability of the relevant ambient temperature design interactive curves given in the current European, American and Australian standards to post-fire S890 UHSS CHS under combined compression and bending was assessed, with post-fire material properties used. The assessment results showed that all design standards exhibited conservative and scattered predictions of residual resistances for S890 UHSS CHS under combined compression and bending at ambient temperature and after exposure to elevated temperatures. The American specification provided more precise predictions of residual failure loads for non-compact and slender (Class 3 and 4) sections than the Eurocode and Australian standard, due to the accurate compression and bending endpoints. In comparison to the American and Australian specifications, the Eurocode resulted in more precise results in predicting residual failure loads of compact (Class 1 and 2) sections, owing to the accurate compression and bending endpoints as well as the nonlinear design interaction curve.

A simple, fast, and robust criterion for predicting fracture load and crack growth path in notched elastoplastic plates under mixed-mode loading

This study assesses the combined in-plane tensile/shear failure of aluminum plates containing notches. With this aim, a numerical method, i.e., the so-called equivalent material concept (EMC) in association with the extended finite element method (XFEM), is introduced to simulate the fracture phenomenon. The predicted failure load, initiation angle, and growth path are compared to experimental results reported for aluminum alloys in the literature to evaluate the functionality of the proposed method. Also, the accuracy of the EMC-XFEM model was compared to the conventional Ductile Damage method. The EMC-XFEM combined model is found to be fast and robust with appropriate accuracy in fracture predictions of ductile samples in comparison with the elastoplastic damage model and experimental data.

Post-buckling damage tolerance of welded omega-stiffened thermoplastic panels with initial damage

Welded omega-stiffened panels made of thermoplastic carbon composite with initial damage in the conduction welded joint are analysed and tested to investigate the damage tolerance in post-buckling. Finite element analyses are performed, using the virtual crack closure technique to investigate skin-stringer separation for both the pristine welded joint and joints with initial damage. A sensitivity study is executed for the initial damage size and location with different geometrical imperfections. Four omega-stiffened panels are tested, of which three have initial damage consisting of a foil at the welded skin-stringer interface. During the test, digital image correlation is used to measure the panels’ deformation to determine the evolution of the buckling shape and the interaction with the initial damage. A high-speed camera is placed on the stringer side of the panel to capture the final failure. The panels fail in post-buckling when skin-stringer separation occurs, starting from the initial damage. The finite element analysis is able to predict the overall structural behaviour well, with conservative failure load predictions for panels with initial damage in the middle stringer. Although the initial buckling shape is predicted well, the buckling shape evolution at higher loads is difficult to predict.

Estimation of load-carrying capacity of cracked RC beams using 3D digital twin model integrated with point clouds and images

Digital twin (DT) is capable of managing, simulating, and future performance prediction of existing infrastructures by integrating three-dimensional (3D) geometric model and finite element (FE) model. This study aims to automatically generate geometric DT of existing RC members using point clouds and incorporate damages detected from images into FE models. An edge-based modeling method was proposed to extract sharp features for geometry reconstruction with incomplete point clouds, and an automated procedure was established for registering images to point clouds, mapping cracks detected in images to FE models, and assigning reduced material properties. Four RC beams were tested in a laboratory to validate the proposed method. Existing cracks were found to have a significant effect on structural capacity and failure mode. The results also showed that the developed FE model produced a good agreement between experimental and predicted failure loads while providing a more efficient and time-saving assessment protocol.

Experimental and numerical investigations of high-strength cold-formed steel multi-limb built-up section columns

This paper investigates the buckling behaviour and load-carrying capacity of G550 high-strength cold-formed steel multi-limb built-up section columns under axial compression. Each built-up section consists of multiple lipped and unlipped channel sections connected by self-tapping screws. The C3U1 section is formed by three C-sections (i.e. lipped channel section) and one U-section (i.e. unlipped channel section), while the C2U2 section is formed by two C-sections and two U-sections. The experimental programme involved tensile coupon tests, measurements of initial geometrical imperfection, and column tests on ten C3U1 and ten C2U2 multi-limb built-up section columns. The numerical modelling programme was then performed, with the nonlinear finite element models created and validated against the experimental results. The applicability of the codified Effective Width Method and Direct Strength Method for predicting the strengths of G550 high-strength cold-formed steel multi-limb built-up section columns, as specified in the American Specification and Australian Standard, was then evaluated. The evaluation results showed that the codified Effective Width Method led to rather conservative and less accurate failure load predictions for G550 high-strength cold-formed steel multi-limb built-up section columns, while the codified Direct Strength Method provided accurate and consistent failure load predictions and thus applicable to the design of G550 high-strength cold-formed steel multi-limb built-up section columns. Concerning the lack of design guidelines specifically for multi-limb built-up sections, a modified Direct Strength Method was thus proposed as an alternative design method and shown to provide accurate failure load predictions.

Bearing–curling interaction of austenitic stainless steel thin sheet bolted connections

The bearing–curling interactive behaviour and capacities of austenitic stainless steel thin sheet bolted connections are studied in this paper, underpinned by testing and numerical modelling. Experiments were firstly conducted on 26 austenitic stainless steel thin sheet bolted connection specimens, including 19 specimens designed with curling and 7 specimens designed without curling. The test failure loads, failure modes, load–in-plane elongation curves and load–out-of-plane deformation curves were fully reported. The experimental programme was followed by a numerical modelling programme, where finite element models were firstly developed to repeat the experimental results and then used to carry out parametric studies to generate a numerical data pool. Based on the obtained numerical data, the influences of end distance, edge distance, longitudinal spacing, transverse spacing and sheet thickness on failure loads of austenitic stainless steel thin sheet bolted connections were discussed. The test and numerical data were used to assess the existing design provisions, as given in the European code and American specification. The assessment results revealed that the European code led to overall accurate but scattered failure load predictions, while the American specification was shown to result in overly unsafe and scattered failure load predictions.

Machine-learning-assisted design of high strength steel I-section columns

High strength steel has been attracting attention in the building industry due to its superior mechanical properties. The accurate design of high strength steel structures is crucial to boost its wide application. In this paper, an accurate and unified design approach for high strength steel I-section columns with different material grades, boundary conditions, geometric dimensions (including cross-section sizes and member lengths) and failure modes is proposed based on machine learning. Firstly, 871 experimental and numerical data were collected from the literature to establish a database. Then, seven machine learning algorithms, including Decision Tree, Random Forest, Support Vector Machine, K-Nearest Neighbour, Adaptive Boosting, Extreme Gradient Boosting and Categorical Boosting, were applied to establish machine learning regression models to predict buckling resistances of high strength steel I-section columns. The model performance was then evaluated through statistic indices, with the evaluation results indicating that the Categorical Boosting trained model yields the highest level of accuracy. Based on the data in the collected database, the regression model trained by Categorical Boosting and existing codified design provisions, as given in the European code and American specification, were assessed and compared. The European code and American specification were found to yield scattered and inaccurate failure load predictions, while the Categorical Boosting trained model led to substantially more accurate and consistent failure load predictions for high strength steel I-section columns with different material grades, boundary conditions, geometric dimensions and failure modes.

Predicting failure initiation at V-notch tips in an AISI 4340 alloy by a continuum damage model

Predicting the fracture in quasi-brittle structures composed of steel alloys near V-notch tips presents a significant challenge. We investigate to which extent the continuum damage approach predicts the failure load FcExp when applied to experiments performed on AISI 4340 alloy specimens tempered at two different temperatures and containing three different V-notch opening angles loaded to fracture under a four-point bending configuration.A series of experiments was performed for the characterization of the material parameters and fracture surface (including triaxiality) for the continuum damage model coupled with the J2 theory of plasticity. Subsequently, this model was implemented within a finite element framework to compute the predicted failure load, termed FcFE. Sensitivity analyses were performed to identify the influence of notch radii and the representation of the supports on FcFE.A strong correlation was observed between FcFE and FcExp for all configurations for both tempering temperatures, with predicted loads falling within the range of experimental observations for all V-notch angles. Additionally, a linear relationship was identified between the increase of FcFE and V-notch radii. These non-linear analyses have also revealed that for these high-strength steel specimens, it is crucial to model supports as linear elastic, as rigid supports led to underestimated FcFE.The presented methodology has shown to be superior in predicting failure loads in these quasi-brittle steel structures compared to other more simplified linear approaches.

Experimental and numerical investigations of S960 hot-rolled ultra-high strength steel seamless circular hollow section beam–columns

The rapid development of manufacturing techniques and material science enables advanced hot-rolled ultra-high strength steel (UHSS) with material grades up to S960 to be available recently. The structural performance of S960 hot-rolled UHSS seamless circular hollow section (CHS) beam–columns manufactured through the advanced fabrication approach was experimentally and numerically investigated and reported in this paper. In physical testing, totally ten beam–column specimens were tested, with the complementary material testing and initial global geometric imperfection measurements through the innovative digital image correlation (DIC) method performed. FE modeling was then carried out; FE models of S960 hot-rolled UHSS seamless CHS beam–columns were established and then validated the test observations in terms of the failure loads and the load–mid-height lateral displacement curves. Parametric studies were thereafter performed, with cross-section dimensions, member lengths and loading combinations varying within a certain range, resulting in the additional 300 data to be acquired. Finally, the applicability of existing design methods, as prescribed in the European code, the Australian standard and the American specification, to S960 hot-rolled UHSS seamless CHS beam–columns was evaluated. It can be concluded from the evaluation results that all the three design codes provide accurate and consistent failure load predictions for S960 hot-rolled UHSS seamless CHS beam–columns.

Influence of Failure-Load Prediction in Composite Single-Lap Joints with Brittle and Ductile Adhesives Using Different Progressive-Damage Techniques.

The usage of adhesively bonded joints, such as single-lap and double-lap joints, is increasing rapidly in aerospace composite structures as a popular alternative to bolts and rivets. Compared to the conventional joining methods such as fastening and riveting, adhesive-bonding technology better prevents damage to composite structures due to the smooth configuration and the mitigation of stress concentration around holes. In this work, the built-in progressive-damage-modeling techniques in Abaqus, including the cohesive zone model (CZM) and the virtual crack closure technique (VCCT), are used to predict the strength and progressive failure of composite single-lap joints subjected to tensile loading. Modeling of an adhesive layer by using a zero/non-zero-thickness cohesive element, cohesive surface, and VCCT is investigated, as is the effect of brittle and ductile adhesives. Two-dimensional finite-element models with different damage-modeling strategies are performed in this study. The failure-load predictions are compared with the experimental results obtained from the literature. For the ductile adhesive, the predicted failure loads using a zero/non-zero-thickness cohesive elements and a cohesive surface are all shown to be in good agreement with the experiments. However, the VCCT technique predicts higher failure loads. For a brittle adhesive, on the other hand, the predictions by zero/non-zero-thickness cohesive elements and cohesive surfaces reveal notable deviations compared to the experimental results. In contrast to the ductile adhesive, the VCCT technique is revealed to be accurate in predicting the brittle adhesive.

Unified machine-learning-based design method for normal and high strength steel I-section beam–columns

High strength steel is regarded as a promising construction material due to its superior mechanical properties. However, the codified failure load predictions for high strength steel welded I-section beam–columns are not accurate in some cases owing to the lack of relevant design codes for high strength steel structures. In addition, current design codes ignore the interaction effect of the cross-section plate elements, leading to the inaccuracy of codified predictive ultimate resistances for both normal and high strength steel beam–columns. In this paper, a unified and accurate design method was proposed based on machine learning for both normal and high strength steel welded I-section beam–columns failing by different failure modes. Firstly, a total of 812 experimental and numerical data on welded I-section beam–columns with various steel grades, geometric dimensions, including cross-section dimensions and member lengths, and failure modes, including global buckling, local buckling and local–global interactive buckling were collected to establish a database. Seven machine learning algorithms, including Decision Tree, Random Forest, Support Vector Machine, K-Nearest Neighbour, Adaptive Boosting, Extreme Gradient Boosting and Categorical Boosting were applied to develop regression models to predict failure loads. Based on the established database, each machine learning model was then trained and key hyperparameters were optimised. The model performance was evaluated through a series of statistical indicators and the feature importance analysis, and the evaluated results indicated that the XG-trained regression model had the highest level of accuracy. Finally, the predictions given by the XG-trained regression model were compared with those of the existing codified design provisions, as given in Eurocode and American codes. The evaluation results indicated that the codified predictive bearing capacities of I-section beam–columns were scattered and inaccurate, while the XG-trained regression model provided substantially improved failure load predictions.

Prediction of fracture failure and fracture parameters for dam gallery concrete specimens of arbitrary size and age via boundary effect model and fracture extreme theory

Cracking-associated problems may occur in the construction and operation periods of dam galleries, necessitating attention to the fracture characteristics of gallery concrete. The fracture parameters of concrete exhibit size effects and also change with age. A correct evaluation of the cracking risk or crack stability of gallery structures at any given time requires a comprehensive understanding of both the size effect and time-variant characteristics of the gallery concrete fracture parameters. In the present study, 75 wedge-splitting specimens, with effective heights ranging from 200 mm to 600 mm, were cast using gallery concrete produced by the concrete mixing system at the Baihetan Dam construction site. Subsequently, fracture tests were conducted on these specimens at curing ages spanning from 7 days to 90 days. According to the test results, the fracture parameters of concrete with a specific size exhibited an increasing trend with age within 90 days, while the fracture parameters of concrete at specific ages show a significant size effect, tending to stabilize as the effective depth of specimens gradually increases. The boundary effect model was utilized for analyzing the fracture test results of concrete specimens at different ages, yielding the size-independent double-K fracture parameters and scale parameters for concrete at each age, along with their time-varying patterns. Subsequently, equations for predicting the failure loads of concrete specimens of any age and size were established. Based on the prediction results of failure loads, the double-K fracture parameters of concrete specimens of any age and size were solved by the fracture extreme theory. The predicted failure loads and fracture parameters were in good agreement with the experimental results. The findings of this study can be applied to the full lifecycle crack risk analysis or crack stability assessment of Baihetan Dam gallery structures.

Experimental study of concrete-filled stainless steel tubular stub columns with circular and square cross-sections subjected to combined compression and bending

This paper presents an experimental study into the structural behaviour and strength of concrete-filled stainless steel tubular stub columns with circular and square cross-sections subjected to combined compression and bending moment. A total of sixteen concrete-filled stainless steel tubular (CFSST) stub columns were tested, including two section types (circular and square hollow sections), two grades of concrete infill (C30 and C60), two thicknesses of tube wall for each cross-section (6 and 10 mm), and five loading eccentricity ratios (0, 0.2, 0.3, 0.4 and 0.5). The CFSST stub column specimens were loaded in compression, with different loading eccentricities applied to achieve a wide range of axial load-to-bending moment ratios. This research provides a comprehensive report on the experimental methodology and subsequent observations, including the failure modes, load-deformation curves, axial load-bending moment curves, strain development at the key locations and values of ductility index. It can be observed that for circular CFSST columns, ultimate load decreased by roughly 70% with an increase in loading eccentricity ratios from 0 to 0.5, while for square columns, the reduction was about 50% under same conditions. The experimental results were used to evaluate if the existing design provisions for carbon steel-concrete composite structures is capable of designing the investigated CFSST stub columns. It was found that the mean ultimate load to predicted failure load ratios are 1.25, 1.32, and 1.36, with coefficients of variations (COV) equal to 0.08, 0.09 and 0.11, for the European, American, and Chinese codes, respectively. Consequently, the design approach specified in the Chinese code led to the most conservative and scattered strength predictions among the three codified design approaches. In contrast, the European code provides the most precise predictions of the test results, though there still remains scope for improvements in the ultimate resistance predictions of CFSST stub columns subjected to combined compression and bending.

In-plane compressive responses and failure behaviors of composite sandwich plates with resin reinforced foam core

The paper presented an experimental study on the effect of the resin reinforced core configuration and core thickness on in-plane compressive responses and failure behaviors of composite sandwich specimens. Two resin reinforced core machining configurations were designed with three core thickness along. In-plane compressive load, displacement, strains on both sides, and failure morphology were closely monitored during the loading process. Meanwhile, the theoretical method also was supplementary to forecast the failures of sandwich structures. It was found that the enhancement of grooved, perforated holes and contour cut (GPC) core was better than double-side grooved and perforated hole (DGP) core to improve the in-plane compressive capacity of sandwich specimens for all thick cores. The core fracture or skin/core debonding failure of sandwich specimens resulted in an instant drop of in-plane compressive load, and the global buckling led to a slower reduction. The failure mode changed from global buckling to skin/core debonding at both sides as the core thickness increased for the Plain core sandwich specimen; switched from global buckling to a combined failure of core fracture and skin/core debonding at both sides, and then to skin/core debonding at both sides for the DGP core sandwich specimen; the skin/core debonding at the shallow side occurred for all GPC core specimens. The slight buckling trace of strains before the peak load probably triggered the skin/core debonding of sandwich specimens. The theoretical method could well forecast failure loads and corresponding failure modes of sandwich specimens with the 15 mm thick core, and reasonably predict failure loads for sandwich specimens with 30 mm and 45 mm thick cores.

Web crippling of stainless steel built-up I-sections under End-Two-Flange loading: Tests, simulations and design

This paper presents experimental and numerical investigations into the web crippling behaviour and load-carrying capacity of stainless steel built-up I-section members under End-Two-Flange (ETF) concentrated transverse loading. An experimental programme was conducted on 23 austenitic and duplex stainless steel built-up I-section specimens, with each consisting of two identical press-braked channel sections assembled back-to-back by means of self-tapping screws. Following the experimental programme, a numerical modelling programme was performed, where finite element models were firstly developed to replicate the tests and then used to conduct parametric studies. Based on the test and numerical data, the existing design rules for stainless steel built-up I-section members failing by web crippling, as set out in the current European, American and Australian/New Zealand design standards, were assessed. The comparisons indicated that the European and Australian/New Zealand design standards resulted in overly conservative and rather scattered failure load predictions, while the American design standard led to less scattered failure load predictions, but with many predictions on the unsafe side. Therefore, an improved design approach was proposed and shown to provide substantially improved failure load predictions for stainless steel built-up I-section members under End-Two-Flange loading.