Manufacturing, testing and analysis of 3D printed hybrid endplate connections
Author(s)
Dai, Xiaowei
Xing, Wang
Ye, Jun
Quan, Guan
Gardner, Leroy
Type
Journal Article
Abstract
Wire arc additive manufacturing (WAAM) technology is becoming increasingly widely used in the fabrication of large-scale metal components in engineering structures. By combining WAAM with conventionally manufactured structural elements, more efficient, cost-effective and customized structures can be produced. To explore the potential of this hybrid construction concept further, steel endplate connections, formed through the deposition of WAAM steel material onto conventional cold-formed steel hollow sections, are studied herein. A total of 4 groups of hybrid endplate connections, designed with various thicknesses, shapes and deposition strategies, were manufactured through CMT-WAAM. Material tests were conducted on both the deposited material and the substrate hollow steel sections. The geometrical dimensions of the specimens were measured via 3D laser scanning. Tests were then carried out to determine the failure modes, moment-rotation responses and capacities of the hybrid endplate connections. Digital Image Correlation (DIC) was used to record the structural responses of the specimens throughout testing. All the examined hybrid endplate connection specimens failed in the endplates and demonstrated excellent bending and rotation capacities. The printing strategy and layer orientations were found to have limited impact on the material and connection behaviour. The results of the connection tests were compared against the predictions from existing design methods in terms of the failure modes, yield capacity and ultimate capacity. Traditional yield line and T-stub analysis methods captured the performance and failure modes of the hybrid endplate connection accurately, with the average ratios of predicted-to-test yield and ultimate capacities being 0.97 and 0.91, respectively. The results demonstrate the potential and efficiency of using WAAM to produce hybrid bolted connections in the construction industry.
Date Issued
2026-03-01
Date Acceptance
2025-12-21
Citation
Engineering Structures, 2026, 350
ISSN
0141-0296
Publisher
Elsevier BV
Journal / Book Title
Engineering Structures
Volume
350
Copyright Statement
Copyright © 2025 Elsevier Ltd. This is the author’s accepted manuscript made available under a CC-BY licence in accordance with Imperial’s Research Publications Open Access policy (www.imperial.ac.uk/oa-policy)
License URL
Publication Status
Published
Article Number
121993
Date Publish Online
2025-12-24