Metal 3D‐Printing for Repair of Steel Structures

This work employs an innovative technique, wire arc additive manufacturing (WAAM) which is a type of directed energy deposition, for fatigue strengthening of cracked steel components. Different steel plates with a central crack were tested under high‐cycle fatigue loading regime, including a reference plate, a plate repaired by WAAM with as‐deposited profile, and a plate repaired by WAAM and subsequently machined to reduce stress concentration factors. Corresponding finite element simulation was conducted to provide a better understanding on the mechanism of WAAM‐repair. The existing central crack in the reference plate propagated and led to a rupture after 0.94 million cycles, while those in the two WAAM‐repaired plates did not propagate, due to the increased net cross‐section and the compressive stresses induced by the depositing process. However, in the second plate, a new crack initiated at the root of WAAM profile as a result of local stress concentration, and the fatigue life reached 2.2 million cycles (2.3 times as the reference plate). The third plate, on the other hand, survived more than 9 million fatigue cycles with no visible degradation, thanks to its smooth machined profile. The findings of this work indicate that WAAM repair shows great potential as a technique to address fatigue‐related damages in steel structures.