Experimental and Theoretical Research on Welded Aluminium X‐Joints

Aluminium provides many advantages as a construction material in civil engineering, such as for example light weight, functionality by extruded profiles and corrosion resistance. It is obvious to use these advantages also for trusses. However, most aluminium alloys develop zones of weakening due to welding. The so called heat affected zones (HAZ) reduce the load‐bearing capacity of welded aluminium joints by up to 50%. Consequently, the design and execution of welded X‐joints within lattice girders are challenging. Indeed, the design of welded aluminium X‐joints is not specifically treated in EN 1999. Until now, the calculation of aluminium welded X‐joints relies on the steel standard EN 1993‐1‐8, which does not take into account the characteristic of aluminium. This results in errors and inefficient design. Thus, in this experimental research project the behavior of welded X‐joints in real‐scale models is explored. To this purpose, tests have been carried out on lattice girders made from aluminium alloy EN AW 6082 T6. In total, six girders with varying coefficient β and shape of the hollow section of brace members have been investigated. Thereby, the girders were loaded vertically until the failure of the X‐joints. Strains at the brace and chord members were measured by strain gauges and respective stresses were derived. In addition, a comparative analysis between experimentally and theoretically ‐ based on Eurocodes (EN 1993 part 1‐8 and EN 1999 part 1‐1) ‐ obtained results has been made. The analysis shows that the reduction of the load‐bearing capacity of welded aluminium X‐joints due to the HAZ is not constant but varies with the value of coefficient β and the shape of the cross‐section of the brace member. Obviously, the design of welded aluminium X‐joints based on EN 1993‐1‐8 applying a constant value for the HAZ does not reflect the true behavior of these joints as it leads to a quite conservative design approach.