PSI - Issue 77

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ScienceDirect

Procedia Structural Integrity 77 (2026) 198–206 Structural Integrity Procedia 00 (2026) 000–000 Structural Integrity Procedia 00 (2026) 000–000

www.elsevier.com / locate / procedia www.elsevier.com / locate / procedia

© 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers © 2026 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of ICSI organizers. Keywords: Additve manufacturing; PBF-LB / M; Welding; Dissimilar Welding; Digital Image Correlation The results provide critical insights into the structural integrity and performance of welded connections between AM and con ventionally manufactured steels. These findings support the advancement of AM applications in construction, particularly for the development of optimized and reliable structural connections. © 2026 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of ICSI organizers. Keywords: Additve manufacturing; PBF-LB / M; Welding; Dissimilar Welding; Digital Image Correlation International Conference on Structural Integrity Implementation of additively manufactured parts in the construction sector via welding Jakob Blankenhagen a, ∗ , Christina Radlbeck a , Kevin Hoefer b , Jonas Hensel b ,Martin Mensinger a a Chair for Metal Structures, Technical University of Munich, Arcisstrasse 21, 80333 Munich b Chair of Welding Engineering, Chemnitz University of Technology Abstract Additive Manufacturing (AM) is increasingly adopted across industrial sectors, including construction. However, its application in large-scale structural elements remains limited due to the build size constraints of most AM processes. A promising strategy to overcome these limitations is the integration of additively manufactured components with conventional semifinished elements. Optimized AM nodes in frameworks, for example, can improve load distribution and overall structural e ffi ciency. Welding pro vides a viable method to integrate such nodes into conventional steel structures. Since structural steels are not typically processed by AM due to powder-related corrosion issues, dissimilar “black-and-white” connections between additively manufactured and conventionally produced steels require careful characterization to ensure structural integrity. This study investigates the mechanical performance of dissimilar joints between additively manufactured high-manganese, fully austenitic C + N steel (Printdur ® HSA) and structural steel (S460). The AM plates were produced by the Powder Bed Fusion–Laser Beam of Metals (PBF-LB / M) process with dimensions of 200 × 100 × 6 mm and subsequently welded to S460NL plates of identical size using two methods: laser welding and Metal Inert Gas (MIG) welding with 18 8 Mn filler. Tensile tests were performed to evaluate joint strength, and Digital Image Correlation (DIC) was applied to analyze strain distribution and failure mechanisms. In addition, the heat-a ff ected zone (HAZ) behavior of Printdur ® HSA was simulated by dilatometer heat treatments at three peak temperatures and four t 8 / 5 cooling times, followed by tensile testing. The results provide critical insights into the structural integrity and performance of welded connections between AM and con ventionally manufactured steels. These findings support the advancement of AM applications in construction, particularly for the development of optimized and reliable structural connections. International Conference on Structural Integrity Implementation of additively manufactured parts in the construction sector via welding Jakob Blankenhagen a, ∗ , Christina Radlbeck a , Kevin Hoefer b , Jonas Hensel b ,Martin Mensinger a a Chair for Metal Structures, Technical University of Munich, Arcisstrasse 21, 80333 Munich b Chair of Welding Engineering, Chemnitz University of Technology Abstract Additive Manufacturing (AM) is increasingly adopted across industrial sectors, including construction. However, its application in large-scale structural elements remains limited due to the build size constraints of most AM processes. A promising strategy to overcome these limitations is the integration of additively manufactured components with conventional semifinished elements. Optimized AM nodes in frameworks, for example, can improve load distribution and overall structural e ffi ciency. Welding pro vides a viable method to integrate such nodes into conventional steel structures. Since structural steels are not typically processed by AM due to powder-related corrosion issues, dissimilar “black-and-white” connections between additively manufactured and conventionally produced steels require careful characterization to ensure structural integrity. This study investigates the mechanical performance of dissimilar joints between additively manufactured high-manganese, fully austenitic C + N steel (Printdur ® HSA) and structural steel (S460). The AM plates were produced by the Powder Bed Fusion–Laser Beam of Metals (PBF-LB / M) process with dimensions of 200 × 100 × 6 mm and subsequently welded to S460NL plates of identical size using two methods: laser welding and Metal Inert Gas (MIG) welding with 18 8 Mn filler. Tensile tests were performed to evaluate joint strength, and Digital Image Correlation (DIC) was applied to analyze strain distribution and failure mechanisms. In addition, the heat-a ff ected zone (HAZ) behavior of Printdur ® HSA was simulated by dilatometer heat treatments at three peak temperatures and four t 8 / 5 cooling times, followed by tensile testing.

∗ Corresponding author. Tel.: + 49-89-25172. E-mail address: jakob.blankenhagen@tum.de ∗ Corresponding author. Tel.: + 49-89-25172. E-mail address: jakob.blankenhagen@tum.de

2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers 10.1016/j.prostr.2026.01.027 2210-7843 © 2026 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of ICSI organizers. 2210-7843 © 2026 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of ICSI organizers.