Combining Wire and Arc Additive Manufacturing and Selective Paste Intrusion for Additively Manu-factured Structural Concrete

Fundamental Investigations on the Effect of Heat Exposure by WAAM on the Rheological and Intrusion Behavior of Cement Paste in the Particle Bed During Selective Paste Intrusion

Authors

DOI:

https://doi.org/10.52825/ocp.v1i.75

Keywords:

Additive Manufacturing, Concrete, Particle-Bed, Selective Paste Intrusion, Reinforcement, Wire and Arc Additive Manufacturing, SPI, WAAM, Rheology, Temperature

Abstract

The Selective Paste Intrusion (SPI) is an additive manufacturing method in which thin layers of aggregates are bond selectively by cement paste only where the structure shall arise. In this way, concrete elements with complex geometries and structures can be produced. To meet the optimum between required layer bonding and sufficient shape accuracy, the rheological properties of the cement paste, i.e., its yield stress and dynamic viscosity, are crucial [1, 2]. The combination of the SPI process and the Wire and Arc Additive Manufacturing (WAAM) process enables the production of free-formed, high-strength reinforced concrete elements, which opens up a wide range of applications. However, the WAAM process generates high temperatures, which affect the rheological properties of the cement paste and thus the printing quality [3, 4]. Therefore, we analyzed the effect of external temperature loads on the rheological performance of cement paste over the entire SPI production period and derived a maximum acceptable temperature load for the combination of SPI and WAAM. The experiments showed decreasing viscosity and increasing yield stress values by stepwise increasing the paste temperature from 20 °C to 60 °C. Between 60 °C and 70 °C, the rheological behavior suddenly changed, and both viscosity and yield stress instantly increased to a multiple of their initial values. In a subsequent numerical simulation of the intrusion behavior of the paste in the particle bed, we could show that the high yield stress and viscosity lead to poor paste penetration and thus insufficient layer bonding, whereas paste temperatures up to 60 °C are not detrimental to the SPI process. Therefore, the results demonstrate that the combination of SPI and WAAM is possible if the WAAM process is adjusted by e.g. cooling strategies, increased distance of the welding point from the particle bed, or increased time intervals between the welding points to avoid paste temperatures exceeding 60 °C.

Downloads

Download data is not yet available.

References

Weger, D. and Gehlen, C. 2021. Particle-Bed Binding by Selective Paste Intrusion-Strength and Durability of Printed Fine-Grain Concrete Members. Materials (Basel, Switzerland) 14, 3. DOI: https://doi.org/10.3390/ma14030586.

Weger, D., Pierre, A., Perrot, A., Kränkel, T., Lowke, D., and Gehlen, C. 2021. Penetra-tion of Cement Pastes into Particle-Beds: A Comparison of Penetration Models. Mate-rials (Basel, Switzerland) 14, 2. DOI: https://doi.org/10.3390/ma14020389.

Weger, D. 2020. Additive Fertigung von Betonstrukturen mit der Selective Paste Intru-sion – SPI / Additive manufacturing of concrete structures by Selective Paste Intrusion - SPI. Dissertation, Munich.

Weger, D., Baier, D., Straßer, A., Prottung, S., Kränkel, T., Bachmann, A., Gehlen, C., and Zäh, M. Reinforced Particle-Bed Printing by Combination of the Selective Paste In-trusion Method with Wire and Arc Additive Manufacturing – A First Feasibility Study 28, 978–987. DOI: https://doi.org/10.1007/978-3-030-49916-7_95.

Weger, D., Gehlen, C., Lowke, D. Additive Fertigung von Betonbauteilen durch selekti-ve Zementleim-Intrusion. Proceedings of Ibausil 2018.

Lowke, D., Dini, E., Perrot, A., Weger, D., Gehlen, C., and Dillenburger, B. 2018. Parti-cle-bed 3D printing in concrete construction – Possibilities and challenges. Cement and Concrete Research 112, 50–65. DOI: https://doi.org/10.1016/j.cemconres.2018.05.018.

Pierre, A., Weger, D., Perrot, A., and Lowke, D. 2018. Penetration of cement pastes into sand packings during 3D printing: analytical and experimental study. Mater Struct 51, 1. DOI: https://doi.org/10.1617/s11527-018-1148-5.

Weger, D., Lowke, D., Gehlen, C. 3D Printing of Concrete Structures with Calcium Sili-cate based Cements using the Selective Binding Method - Effects of Concrete Tech-nology on Penetration Depth of Cement Paste. Proceedings of Hipermat 2016 - 4th In-ternational Symposium on Ultra-High Performance Concrete and High Performance Construction Materials 2016.

Weger, D., Lowke, D., Gehlen, C., Talke, D., Henke, K. Additive manufacturing of con-crete elements using selective cement paste intrusion – effect of layer orientation on strength and durability. Proceedings of RILEM 1st International Conference on Con-crete and Digital Fabricaton 2018.

Roussel, N. and Coussot, P. 2005. “Fifty-cent rheometer” for yield stress measure-ments: From slump to spreading flow. Journal of Rheology 49, 3, 705–718. DOI: https://doi.org/10.1122/1.1879041.

Roussel, N., Stefani, C., and Leroy, R. 2005. From mini-cone test to Abrams cone test: measurement of cement-based materials yield stress using slump tests. Cement and Concrete Research 35, 5, 817–822. DOI: https://doi.org/10.1016/j.cemconres.2004.07.032.

Mechtcherine, V., Grafe, J., Nerella, V. N., Spaniol, E., Hertel, M., and Füssel, U. 2018. 3D-printed steel reinforcement for digital concrete construction – Manufacture, me-chanical properties and bond behaviour. Construction and Building Materials 179, 125–137. DOI: https://doi.org/10.1016/j.conbuildmat.2018.05.202.

Larrard, F. de, Ferraris, C. F., and Sedran, T. 1998. Fresh concrete: A Herschel-Bulkley material. Mater Struct 31, 7, 494–498. DOI: https://doi.org/10.1007/BF02480474.

Mezger, T.G. 2006. Das Rheologie Handbuch. Für Anwender von Rotations- und Oszil-lations-Rheometern. Vincentz, Hannover, Germany.

Lee, D. K. and Choi, M. S. 2018. Standard Reference Materials for Cement Paste: Part III-Analysis of the Flow Characteristics for the Developed Standard Reference Material According to Temperature Change. Materials (Basel, Switzerland) 11, 10. DOI: https://doi.org/10.3390/ma11102001.

Martini, S. A. and Nehdi, M. 2009. Coupled Effects of Time and High Temperature on Rheological Properties of Cement Pastes Incorporating Various Superplasticizers. J. Mater. Civ. Eng. 21, 8, 392–401. DOI: https://doi.org/10.1061/(ASCE)0899-1561(2009)21:8(392).

Wang, Y., Wu, A., Ruan, Z., Wang, H., Wang, Y., and Jin, F. 2018. Temperature Ef-fects on Rheological Properties of Fresh Thickened Copper Tailings that Contain Ce-ment. Journal of Chemistry 2018, 1–8. DOI: https://doi.org/10.1155/2018/5082636.

Haist, M. 2010. Zur Rheologie und den physikalischen Wechselwirkungen bei Ze-mentsuspensionen. Dissertation. Zugl.: Karlsruhe, Univ., Diss., 2009. Karlsruher Reihe Massivbau, Baustofftechnologie, Materialprüfung H. 66. KIT Scientific Publ, Karlsruhe.

Gallucci, E., Zhang, X., and Scrivener, K. L. 2013. Effect of temperature on the micro-structure of calcium silicate hydrate (C-S-H). Cement and Concrete Research 53, 185–195. DOI: https://doi.org/10.1016/j.cemconres.2013.06.008.

Lothenbach, B., Winnefeld, F., Alder, C., Wieland, E., and Lunk, P. 2007. Effect of temperature on the pore solution, microstructure and hydration products of Portland cement pastes. Cement and Concrete Research 37, 4, 483–491. DOI: https://doi.org/10.1016/j.cemconres.2006.11.016.

Kjellsen, K. O. and Detwiler, R. J. 1992. Reaction kinetics of portland cement mortars hydrated at different temperatures. Cement and Concrete Research 22, 1, 112–120. DOI: https://doi.org/10.1016/0008-8846(92)90141-H.

Damidot, D. and Glasser, F. P. 1992. Thermodynamic investigation of the CaO-Al2O3-CaSO4-H2O system at 50°C and 85°C. Cement and Concrete Research 22, 6, 1179–1191. DOI: https://doi.org/10.1016/0008-8846(92)90047-y.

Perkins, R. B. and Palmer, C. D. 1999. Solubility of ettringite (Ca6[Al(OH)6]2(SO4)3 · 26H2O) at 5–75°C. Geochimica et Cosmochimica Acta 63, 13-14, 1969–1980. DOI: https://doi.org/10.1016/S0016-7037(99)00078-2.

Lothenbach, B., Matschei, T., Möschner, G., and Glasser, F. P. 2008. Thermodynamic modelling of the effect of temperature on the hydration and porosity of Portland ce-ment. Cement and Concrete Research 38, 1, 1–18. DOI: https://doi.org/10.1016/j.cemconres.2007.08.017.

Deschner, F., Lothenbach, B., Winnefeld, F., and Neubauer, J. 2013. Effect of tem-perature on the hydration of Portland cement blended with siliceous fly ash. Cement and Concrete Research 52, 169–181. DOI: https://doi.org/10.1016/j.cemconres.2013.07.006.

Nehdi, M. and Al Martini, S. 2009. Estimating time and temperature dependent yield stress of cement paste using oscillatory rheology and genetic algorithms. Cement and Concrete Research 39, 11, 1007–1016. DOI: https://doi.org/10.1016/j.cemconres.2009.07.011.

Nehdi, M. and Al Martini, S. 2007. Effect of Temperature on Oscillatory Shear Behavior of Portland Cement Paste Incorporating Chemical Admixtures. J. Mater. Civ. Eng. 19, 12, 1090–1100. DOI: https://doi.org/10.1061/(ASCE)0899-1561(2007)19:12(1090).

Varshney, A., Gohil, S., Chalke, B. A., Bapat, R. D., Mazumder, S., Bhattacharya, S., and Ghosh, S. 2017. Rheology of hydrating cement paste: Crossover between two ag-ing processes. Cement and Concrete Research 95, 226–231. DOI: https://doi.org/10.1016/j.cemconres.2017.02.034.

Pierre, A., Weger, D., Perrot, A., and Lowke, D. 2020. Additive Manufacturing of Ce-mentitious Materials by Selective Paste Intrusion: Numerical Modeling of the Flow Us-ing a 2D Axisymmetric Phase Field Method. Materials (Basel, Switzerland) 13, 21. DOI: https://doi.org/10.3390/ma13215024.

Published

2022-02-15

How to Cite

Straßer, A., Weger, D., Matthäus, C., Kränkel, T., & Gehlen, C. (2022). Combining Wire and Arc Additive Manufacturing and Selective Paste Intrusion for Additively Manu-factured Structural Concrete: Fundamental Investigations on the Effect of Heat Exposure by WAAM on the Rheological and Intrusion Behavior of Cement Paste in the Particle Bed During Selective Paste Intrusion. Open Conference Proceedings, 1, 61–72. https://doi.org/10.52825/ocp.v1i.75
Received 2021-09-30
Accepted 2022-02-04
Published 2022-02-15

Funding data