Particle-based Simulation of Crack Propagation in Structural Connections Produced with Wire Arc Additive Manufacturing

  • Olsson, Jens (Chalmers Industriteknik)
  • Ander, Mats (Chalmers University of Technology)
  • Borgström, Oscar (Foster + Partners)
  • Larsson, Simon (Tyréns)
  • Tibuzzi, Edoardo (AKT II)
  • Williams, Chris (Chalmers University of Technology)

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Force Flux Peridynamics is a particle method which can be used to simulate yielding and brittle fracture. This paper explores how FFPD can support the design of lightweight metal components in building structures produced with Wire Arc Additive Manufacturing (WAAM). WAAM is a relatively new technology that uses a wire electrode to deposit metal layer-by-layer to create three-dimensional structures. This process has the potential to significantly reduce the embodied carbon in building structures by reducing the weight of the structural connections and hence the weight of all other structural components. However, the process applied in WAAM for steel components can make these objects susceptible to defects which may compromise their structural integrity and may even lead to fracture. A nodal connection designed for rotational WAAM printing is analyses with FFPD to study its sensitivity to imposed imperfections.