Development of stainless-clad bimetallic steel systems for resilient structures using 3D printing techniques

To achieve an ambitious goal of carbon-neutral Europe by 2050, a new generation of double-sided stainless-clad bimetallic steel (SC) manufactured from cutting-edge 3D printing techniques (WAAM) was developed and investigated in this project, which has promising potential for engineering applications in demanding environments. It typically consists of a substrate layer (mild steel) and two clad layers (stainless steel), which combines the excellent corrosion resistance of stainless steel with the high strength and low cost of conventional mild (CM) steel. The combination of bimetallic steel and 3D printing not only reduces material cost but also minimizes the environmental impact. However, no studies or design standards are available in the literature for such member. This issue is addressed herein. The aim of this project is to develop the innovative WAAM double-sided SC bimetallic steel systems through the testing, numerical analysis and theoretical methods. To achieve this, a series of full-scale laboratory tests will be conducted, including cyclic loading tests, stub column tests, shear tests, bonding tests, and residual stress tests. Following this, a novel numerical modelling technique will be developed to generate a wide range of database. Also, a novel framework will be developed for shape optimization of such members. Finally, a new design approach based on modified European standards (EN 1993-1-4+A1) (2015), along with open-source software, will be proposed, which provides a more accurate strength prediction. The expected outcomes will result in significant economic, social and environmental benefits to European Commission’ construction sector by developing the next-generation 3D printing-based bimetallic steel resilient structures, contributing toward net-zero carbon emissions. This fellowship can serve as a stepping-stone in the fellow’s career, advancing his goal of making a meaningful impact on both society and the global construction industry.