Advanced Design Framework for WAAM-Strengthened Stainless Steel Structural Elements

The project “Advanced Design Framework for WAAM-Strengthened Stainless Steel Structural Elements” tackles the growing need for sustainable and economical infrastructure solutions. Stainless steel offers high strength, corrosion resistance and durability, but its high initial cost and the aging of existing assets demand efficient strengthening strategies. Wire Arc Additive Manufacturing (WAAM), a large-scale 3D printing method, enables targeted deposition of material only where required, reducing waste and cost while enhancing performance. Despite its potential, the structural use of WAAM for stainless steel elements remains largely unexplored, with no established tests, validated models or design guidance.This project will deliver the first comprehensive design-by-analysis framework for WAAM-strengthened stainless steel beams (SSIBs). Work Package 1 will deliver the first large-scale experimental database on the residual stress and flexural behaviour of WAAM-strengthened SSIBs, providing fundamental insights and openly accessible benchmark data. Work Package 2 will establish a robust thermo-mechanical modelling framework for WAAM-induced residual stresses, integrating secondary Python development in ABAQUS. Work Package 3 will establish FE models of WAAM-strengthened SSIBs, using GMNIA method. Existing design methods will be evaluated and refined, leading to a practical design framework.Expected impacts are scientific, by filling a key research gap and advancing WAAM in structural engineering; economic, by demonstrating efficient strengthening strategies that maximise strength-to-cost and durability-to-cost ratios; and societal, by extending infrastructure service life, reducing waste and emissions, and supporting the European Green Deal and UN Sustainable Development Goals. Collaboration with Imperial College London and MX3D ensures strong academic–industrial links and equips the researcher to become a future contributor to Eurocode development.