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@article{Zhang:2026:10.1016/j.tws.2025.114298,
author = {Zhang, M and Meng, X and Hong, W and Kyvelou, P and Gardner, L},
doi = {10.1016/j.tws.2025.114298},
journal = {Thin Walled Structures},
title = {Hybrid tubular joints featuring topology-optimised DED-Arc nodes},
url = {http://dx.doi.org/10.1016/j.tws.2025.114298},
volume = {223},
year = {2026}
}
TY - JOUR
AB - Relative to conventional formative or subtractive manufacturing techniques, additive manufacturing (AM) offers increased geometric freedom, and the potential for enhanced structural efficiency and greater automation. Hybrid construction, which combines conventionally produced structural components with AM parts, is considered the most practical way to deploy metal AM in construction. This study aims to develop an optimisation methodology for hybrid tubular joints, incorporating topology optimisation and printability considerations. The studied tubular joints have an X-shaped configuration, comprising conventionally produced circular hollow section (CHS) members and wire-arc directed energy deposited (DED-Arc) nodes. The DED-Arc nodes were topology optimised, with performance and printability enhanced by imposing stress and overhang constraints, preventing the formation of overly slender elements and excessive overhang angles. The printability was further improved by manual adjustments to satisfy manufacturing requirements. The structural performance of the hybrid joints, including the initial stiffness, ultimate load-bearing capacity, ductility and material efficiency, was assessed through geometrically and materially nonlinear numerical analyses and physical experiments on nine printed joints; five conventional X-joints were also fabricated and tested to provide benchmark results. Overall, the hybrid joints exhibited up to about 80 % higher initial stiffness, 20 % higher load-bearing capacity and 100 % higher capacity-to-mass ratios under biaxial compression compared with the conventionally produced joints, indicating markedly enhanced structural efficiency.
AU - Zhang,M
AU - Meng,X
AU - Hong,W
AU - Kyvelou,P
AU - Gardner,L
DO - 10.1016/j.tws.2025.114298
PY - 2026///
SN - 0263-8231
TI - Hybrid tubular joints featuring topology-optimised DED-Arc nodes
T2 - Thin Walled Structures
UR - http://dx.doi.org/10.1016/j.tws.2025.114298
VL - 223
ER -