Hybrid tubular joints featuring topology-optimised DED-Arc nodes
File(s)
Published version
Author(s)
Zhang, Minze
Meng, Xin
Hong, Wenxuan
Kyvelou, Pinelopi
Gardner, Leroy
Type
Journal Article
Abstract
Relative to conventional formative or subtractive manufacturing techniques, additive manufacturing (AM) offers increased geometric freedom, and the potential for enhanced structural efficiency and greater automation. Hybrid construction, which combines conventionally produced structural components with AM parts, is considered the most practical way to deploy metal AM in construction. This study aims to develop an optimisation methodology for hybrid tubular joints, incorporating topology optimisation and printability considerations. The studied tubular joints have an X-shaped configuration, comprising conventionally produced circular hollow section (CHS) members and wire-arc directed energy deposited (DED-Arc) nodes. The DED-Arc nodes were topology optimised, with performance and printability enhanced by imposing stress and overhang constraints, preventing the formation of overly slender elements and excessive overhang angles. The printability was further improved by manual adjustments to satisfy manufacturing requirements. The structural performance of the hybrid joints, including the initial stiffness, ultimate load-bearing capacity, ductility and material efficiency, was assessed through geometrically and materially nonlinear numerical analyses and physical experiments on nine printed joints; five conventional X-joints were also fabricated and tested to provide benchmark results. Overall, the hybrid joints exhibited up to about 80 % higher initial stiffness, 20 % higher load-bearing capacity and 100 % higher capacity-to-mass ratios under biaxial compression compared with the conventionally produced joints, indicating markedly enhanced structural efficiency.
Date Issued
2026-04-01
Date Acceptance
2025-11-23
Citation
Thin-Walled Structures, 2026, 223
ISSN
0263-8231
Publisher
Elsevier BV
Journal / Book Title
Thin-Walled Structures
Volume
223
Copyright Statement
© 2025 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).
License URL
Publication Status
Published
Article Number
114298
Date Publish Online
2025-11-24