Automated fabrication – Alper Kanyilmaz

Metal 3D Printing (Metal Additive Manufacturing)

In cooperation with multiple players (architects, manufacturers, producers) and a worlwide research and industrial network, Dr. Kanyilmaz has been studying new tubular joint shapes using metal 3D printing to maximize the structural performance and minimize fabrication complexity to reduce costs, increase customization and cut waste as well as the carbon footprint of the AEC industry. He is currently coordinating the EU-funded research project ConstructAdd.

Video showing the team of ConstructAdd project

More details can be read in these articles:

Alessandro Menghini, Simone Maffia, Ali Gökhan Demir, Alper Kanyilmaz, Filippo Berto, Carlo Andrea Castiglioni, Barbara Previtali, Performance of laser metal deposition on hot-rolled stainless steel for hybrid steel structures, Construction and Building Materials, Volume 443, 2024, https://doi.org/10.1016/j.conbuildmat.2024.137744.

Kanyilmaz A, Ali Gökhan Demir, Martina Chierici, Filippo Berto, Leroy Gardner, Sastry Yagnanna Kandukuri, Paul Kassabian, Takuya Kinoshita, Andrea Laurenti, Ingrid Paoletti, Anton du Plessis, Seyed Mohammad Javad Razavi, Role of metal 3D printing to increase quality and resource-efficiency in the construction sector, Additive Manufacturing, Volume 50, 2022, 102541, ISSN 2214-8604, https://doi.org/10.1016/j.addma.2021.102541

Kanyilmaz, A., Berto, F., Paoletti I., Caringal, R.J., Mora, S., Nature-inspired optimization of tubular joints for metal 3D printing, Struct Multidisc Optim (2020). https://doi.org/10.1007/s00158-020-02729-7, Springer Nature

Chierici, M., Demir, A.G., Kanyilmaz, A., Berto F., Castiglioni, C.A, Previtali B.,. Hybrid manufacturing of steel construction parts via arc welding of LPBF-produced and hot-rolled stainless steels. Prog Addit Manuf (2023). https://doi.org/10.1007/s40964-023-00466-z

Steel joint fabrication using laser cutting

Dr. Kanyilmaz and his team are at the forefront of innovating tubular steel structure joints through Laser Cutting Technology (LCT), aiming to enhance steel construction by leveraging the exceptional structural and aesthetic qualities of steel hollow sections. He has been coordinating the EU-funded research project LASTTS, where a large multi-national and interdisciplinary team has been testing the essential tubular joint components to contribute to the development of a new, comprehensive experimental database.

Up to day, 36 two-way steel joints have been tested under monotonic gravity, opposite bending and shear loading conditions. The new joint configurations performed better than the conventional tubular joint options with up to 2.5 times more resistance and 10 times more stiffness. The superior structural performance translated in significant economic and environmental benefits (up to 35% saving in steel frame costs).

*Load testing in the LCT joints from the LASTEICON project*

Video showing Laser cutting on the tubular profiles

Laser cutting and tubular construction, economic and environmental benefits

More details can be read in these articles:

Mouad Madhouni, Maël Couchaux, Mohammed Hjiaj, Alper Kanyilmaz, Passing-through I-plates-to-SHS moment resisting joints subjected to symmetric bending moments, Thin-Walled Structures, 2024, 112442, ISSN 0263-8231, https://doi.org/10.1016/j.tws.2024.112442

Couchaux M., Vyhlas V., Kanyilmaz A., Hjiaj M., Passing-through I-beam-to-CHS column joints made by laser cutting technology: Experimental tests and design model, Journal of Constructional Steel Research, Volume 176, 2021, 106298, ISSN 0143-974X, https://doi.org/10.1016/j.jcsr.2020.106298

Das R., Kanyilmaz A., Couchaux M., Hoffmeister B., Degee H., Characterization of moment resisting I-beam to circular hollow section column connections resorting to passing-through plates, Engineering Structures, Volume 210, 2020, 110356, ISSN 0141-0296, https://doi.org/10.1016/j.engstruct.2020.110356

Kanyilmaz, A., Castiglioni C.A., Fabrication of laser cut I-beam-to-CHS-column steel joints with minimized welding, Journal of Constructional Steel Research, Volume 146, 2018, Pages 16-32, ISSN 0143-974X, https://doi.org/10.1016/j.jcsr.2018.02.039

Kanyilmaz, A., The problematic nature of steel hollow section joint fabrication, and a remedy using laser cutting technology: A review of research, applications, opportunities, Engineering Structures, Volume 183, 2019, Pages 1027-1048, ISSN 0141-0296, https://doi.org/10.1016/j.engstruct.2018.12.080

Menghini A., Kanyilmaz A., Calado L., Castiglioni C.A., Experimental Assessment of the Behavior of Tubular Truss Girder Joints Fabricated with Laser Cutting Technology (2023) Journal of Structural Engineering (United States), 149 (6), https://doi.org/10.1061/JSENDH.STENG-12019

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