Recent Advancements in Development and Application of an Iron-based Shape Memory Alloy at Empa.

The Fe-SMA developed at the Swiss Federal Laboratories for Materials Science and Technology (Empa) has an alloy composition of Fe-17Mn-5Si-10Cr-4Ni-1(V,C) and exhibits an excellent shape memory effect on heating at 160 °C or above. The shape memory effect feature equips Fe-SMA with a unique self-prestressing ability that can be exploited for many civil engineering applications. In addition to the self-prestressing ability, Fe-SMA has a high elastic modulus (165 GPa), low cost, and high machinability compared to the nickel and copper-based SMAs, which makes it more suitable for structural applications. The current work aims to provide an overview of the recent advancements in the research and development of Fe-SMA at Empa. To this end, the advancements related to the material development, applications of Fe-SMAs in prestressing reinforced concrete (RC) and metallic structures, and  the introduction of Fe-SMA reinforcements to the market alongwith some recent field applications are presented. The paper concludes with an overview of the opportunities and challenges associated with using Fe-SMA reinforcements in civil infrastructure.

Numerical Modeling of Unreinforced Masonry Walls Strengthened with Fe-Based Shape Memory Alloy Strips.

This study presents a new way to improve masonry wall behavior. Masonry structures comprise a significant part of the world's structures. These structures are very vulnerable to earthquakes, and their performances need to be improved. One way to enhance the performances of such types of structures is the use of post-tensioning reinforcements. In the current study, the effects of shape memory alloy as post-tensioning reinforcements on originally unreinforced masonry walls were investigated using finite element simulations in Abaqus. The developed models were validated based on experimental results in the literature. Iron-based shape memory alloy strips were installed on masonry walls by three different configurations, namely in cross or vertical forms. Seven macroscopic masonry walls were modeled in Abaqus software and were subjected to cyclic loading protocol. Parameters such as stiffness, strength, durability, and energy dissipation of these models were then compared. According to the results, the Fe-based strips increased the strength, stiffness, and energy dissipation capacity. So that in the vertical-strip walls, the stiffness increases by 98.1%, and in the cross-strip model's position, the stiffness increases by 127.9%. In the vertical-strip model, the maximum resistance is equal to 108 kN, while in the end cycle, this number is reduced by almost half and reaches 40 kN, in the cross-strip model, the maximum resistance is equal to 104 kN, and in the final cycle, this number decreases by only 13.5% and reaches 90 kN. The scattering of Fe-based strips plays an important role in energy dissipation. Based on the observed behaviors, the greater the scattering, the higher the energy dissipation. The increase was more visible in the walls with the configuration of the crossed Fe-based strips.

RC Structures Strengthened by an Iron-Based Shape Memory Alloy Embedded in a Shotcrete Layer-Nonlinear Finite Element Modeling.

Shape memory alloys (SMAs) have been widely used in civil engineering applications including active and passive control of structures, sensors and actuators and strengthening of reinforced concrete (RC) structures owing to unique features such as the shape memory effect and pseudo-elasticity. Iron-based shape memory alloys (Fe-SMAs) have become popular in recent years. Use of iron-based SMAs for strengthening RC structures has received attention in the recent decade due to the advantages it presents, that is, no ducts or anchor heads are required, friction losses do not occur and no space is needed for a hydraulic device to exert force. Accordingly, Fe-SMAs embedded in a shotcrete layer have been used for pre-stressing RC beams at Empa. The aim of this study is to present an approach to model and analyze the behavior of RC members strengthened and pre-stressed with Fe-SMA rebars embedded in a shotcrete layer. The lack of research on developing finite element models for studying the behavior of concrete structures strengthened by iron-based shape memory alloys is addressed. Three-dimensional finite element models were developed in the commercial finite element code ABAQUS, using the concrete damaged plasticity model to predict the studied beams' load-displacement response. The results of the finite element analyses show a considerably good agreement with the experimental data in terms of the beams' cracking load and ultimate load capacity. The effects of different strengthening parameters, including SMA rebar diameter, steel rebar diameter and pre-stressing force level on the beam behavior, were investigated based on the verified finite element models. The results were compared. The load-displacement response of an 18-m concrete girder strengthened and pre-stressed with iron-based SMA bars was examined by the developed finite element model as a case study.

Prestressed Unbonded Reinforcement System with Multiple CFRP Plates for Fatigue Strengthening of Steel Members.

Carbon fiber reinforced polymer (CFRP) composites have exhibited a great potential for strengthening of steel structures. In the current study, an innovative prestressed unbonded reinforcement (PUR) system is introduced for fatigue strengthening of existing steel members. The system relies on a pair of mechanical clamps; each holds multiple CFRP plates and anchors their prestressing forces to the steel substrate via friction. A finite element model was established to optimize the design of the required mechanical components of the system. A set of static and fatigue tests was conducted on the developed mechanical clamps as the key elements of the proposed PUR system. The performance of the PUR system was then evaluated using a set of fatigue tests on two precracked steel plate specimens, one without any strengthening system and the other one strengthened with the proposed PUR system. In the latter specimen, the CFRP plates were prestressed up to about 800 MPa (approximately 30% of the CFRP tensile strength), which resulted in a complete fatigue crack arrest in the precracked steel plate. Furthermore, neither slippage of the mechanical clamps nor any prestress loss in the CFRP plates was observed after 7.5 million fatigue cycles. Based on the promising experimental results, obtained from the sets of fatigue tests performed in the current study, it can be concluded that the proposed PUR system can be considered as an efficient alternative to the conventional bonded reinforcement solutions for fatigue strengthening of damaged steel members.

A Retrofit Theory to Prevent Fatigue Crack Initiation in Aging Riveted Bridges Using Carbon Fiber-Reinforced Polymer Materials.

Most research on fatigue strengthening of steel has focused on carbon fiber-reinforced polymer (CFRP) strengthening of steel members with existing cracks. However, in many practical cases, aging steel members do not yet have existing cracks but rather are nearing the end of their designed fatigue life. Therefore, there is a need to develop a "proactive" retrofit solution that can prevent fatigue crack initiation in aging bridge members. Such a proactive retrofit approach can be applied to bridge members that have been identified to be deficient, based on structural standards, to enhance their safety margins by extending the design service life. This paper explains a proactive retrofit design approach based on constant life diagram (CLD) methodology. The CLD approach is a method that can take into account the combined effect of alternating and mean stress magnitudes to predict the high-cycle fatigue life of a material. To validate the retrofit model, a series of new fatigue tests on steel I-beams retrofitted by the non-prestressed un-bonded CFRP plates have been conducted. Furthermore, this paper attempts to provide a better understanding of the behavior of un-bonded retrofit (UR) and bonded retrofit (BR) systems. Retrofitting the steel beams using the UR system took less than half of the time that was needed for strengthening with the BR system. The results show that the non-prestressed un-bonded ultra-high modulus (UHM) CFRP plates can be effective in preventing fatigue crack initiation in steel members.