The purpose of this research was to investigate the potential application of additive friction stir deposition (AFSD) to repair corroded steel bridge members. AFSD is an emerging solid-state additive manufacturing (AM) technology with many advantageous qualities such as low porosity, low residual stresses, flexibility in material, and a high build rate allowing for large-scale deposits. Two parameters were studied to understand the quality of AFSD on corroded steel: surface roughness and surface cleanliness. Three rounds of depositions were done: AerMet100, a high-strength corrosion-resistant steel, deposited onto AISI 1018 plates, with varying degrees of section loss, sectioned from a bridge taken out-of-service; AISI 1018 steel deposited onto an A572 Gr. 50 plate with 12 holes of varying diameters and depths drilled into the plate to simulate surface roughness; and AISI 1018 steel deposited onto an A572 Gr. 50 plate with mill scale, corrosion, and an industrial three-coat bridge paint system. The repair quality of each deposition was studied using scanning electron microscopy, microhardness testing, and three-point bending. Results from these tests indicated the following: AFSD can sufficiently mix dissimilar steels and result in a fine-grained microstructure; depositing onto a rough surface appeared to aid bonding between the two materials with little to no adverse effects on the repair quality; and finally, depending on the chosen deposition parameters, AFSD can mix foreign surface material into the matrix or mechanically remove the bulk of the foreign surface material appearing to clean the surface during the deposition. / Master of Science / This research investigated the applicability of additive friction stir deposition (AFSD) to repair corroded steel bridge members. AFSD is an emerging technology that can deposit metals without melting and build a part layer by layer similar to 3D printing. Since this process uses relatively low temperatures, the deposited material is not melted thus reducing issues associated with rapid solidification of melted metal. Three studies were conducted to better understand the print quality of AFSD on corroded steel. First, steel was deposited onto a surface with varying sized holes drilled to different depths meant to simulate a corroded surface. Second, a high-strength corrosion-resistant steel was deposited onto a corroded steel plate cut from an old bridge. Last, steel was deposited onto a steel plate with varying prepared surfaces including paint and corrosion. The quality of the depositions was studied through microscopy and mechanical testing. Results from these tests indicated the following: AFSD can sufficiently bond two different types of steels; depositing onto a non-level surface appeared to aid bonding between the two steels; and finally, AFSD can deposit steel onto certain unclean surfaces.
| Identifer | oai:union.ndltd.org:VTETD/oai:vtechworks.lib.vt.edu:10919/103691 |
| Date | 07 June 2021 |
| Creators | Asiatico, Patricia Magistrado |
| Contributors | Civil and Environmental Engineering, Hebdon, Matthew H., Eatherton, Matthew R., Yu, Hang |
| Publisher | Virginia Tech |
| Source Sets | Virginia Tech Theses and Dissertation |
| Detected Language | English |
| Type | Thesis |
| Format | ETD, application/pdf |
| Rights | In Copyright, http://rightsstatements.org/vocab/InC/1.0/ |
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