Student Name: Israel Barreto
Faculty Sponsor: Michael Seek
Institute: Old Dominion University

This project examines the use of Z-shaped cold-formed steel sections in composite floor systems as an alternative to traditional W-shaped beams. Z-sections, known for efficient fabrication and nesting, will be paired and braced to improve structural performance. The study aims to develop Z-sections with depths of 18 in. to 24 in. and thicknesses from 0.5 in. to 0.75 in., comparable to W18, W21, and W24 shapes. The project will involve designing composite floors using these Z-sections and comparing them with traditional systems, focusing on factors including weight, cost, and ease of assembly. The goal of this research is to assess whether Z-sections offer a cost-effective and efficient solution for composite floor systems.

Student Name: Emily Lamos
Faculty Sponsor: Rachel Cross
Institute: University of Cincinnati

This project explores the properties and applications of high-strength structural steel (HS3), particularly ASTM A913 Gr. 80. With its higher yield (65+ ksi) and ultimate strengths, this type of steel lacks strain-hardening compared to traditional steel, posing challenges in its structural applications. The project, part of a larger AISC-funded study, focuses on tensile and compression tests and residual stress measurements of HS3 to provide necessary data for structural design. The goal is to enhance the adoption of HS3 by offering critical performance data, thereby encouraging its use in building components like gravity columns and transfer girders. The results aim to support HS3's implementation in high-rise and seismic applications, promoting wider industry acceptance.

Student Name: Michael Moschella
Faculty Sponsor: Islam Mantawy
Institute: Rowan University

This project focuses on the development of novel seismic fuses using metal 3D printing techniques like Binder Jetting and Direct Metal Laser Sintering (DMLS). These fuses, designed for easy replacement, aim to concentrate seismic damage, protecting the structural integrity of bracing systems and reducing repair costs. Three innovative fuse designs, including a Double Funnel Fuse and Honeycomb Fuse, are optimized for energy dissipation and resilience under cyclic loading. The project’s goal is to enhance the functionality and sustainability of steel structures by creating fuses that efficiently handle seismic loads, preserving the structure’s overall integrity and minimizing downtime. The research includes fuse optimization, 3D printing, and extensive testing to ensure performance.

Student Name: Paul Quinn
Faculty Sponsor: Jason McCormick
Institute: University of Michigan

This project aims to develop cost-effective, robust connections for hollow structural sections (HSS) in seismic moment frames. HSS, known for their strength and light weight, pose challenges in connections due to their geometry, necessitating complex welding or proprietary solutions. The project seeks to explore non-proprietary connections that meet intermediate and special moment frame requirements. Using previous research on collar connections, the project will test various configurations to understand failure conditions and optimize design parameters. The research includes experimental testing and finite element analysis to ensure that the connections effectively transfer seismic loads and adhere to seismic standards, ultimately aiming for practical, affordable solutions for HSS connections in seismic applications.

Student Name: Ryan Turnbull
Faculty Sponsor: Glenn Washer
Institute: University of Missouri - Columbia

The aim of this project is to improve non-destructive evaluation (NDE) methods for detecting defects in CR50 stainless steel welds, which are increasingly used in construction due to their corrosion resistance and cost-effectiveness. Traditional ultrasonic testing faces challenges with stainless steel's coarse grain structure, which causes high attenuation, wave scattering, and beam skewing, complicating flaw detection. This study seeks to address these issues by collecting detailed velocity profiles of ultrasonic waves through CR50 welds, understanding how these velocities affect wave refraction angles according to Snell’s Law, and characterizing wave behavior across different orientations of the welds. This will enhance the accuracy of ultrasonic inspections and support the broader use of CR50 stainless steel in construction.

Student Name: Rebecca Bauman
Faculty Sponsor: Machel Morrison
Institute: University of California, San Diego

This project is part of a broader AISC-sponsored research project aimed at better characterizing ESW-NG butt splice joints, which allows for faster welding (compared to traditional welding techniques) of thick joints in steel structures. Elecroslag Welding is a process with many potential applications, but one in which major data gaps exist with respect to microstructure properties, pass/fail inspection criteria, and analytical models of the resulting weldments. Thus, there is a need to learn more about the ESW process for wider adoption into steel structures.

Bauman’s work will focus primarily on the experimental aspects of the study and will include extensive hands-on data collection and specimen testing. Some of this work will include collecting temperature data during the electroslag welding process, preparation of metallurgical samples to examine microstructure in different regions of the weldment, reduced section tensile tests, and Charpy V-Notch testing. Through this project, Bauman will gain much experience with hands-on testing and interpreting collected data. It will also allow her to assemble results and present them in a technical report that will be publicly available for others who may be interested in researching or using Electroslag Welding.

Student Name: Shirin Raschid Farrokhi
Faculty Sponsor: Ryan Sherman
Institute: Georgia Tech

This project will further explore the mechanical behavior, in particular fatigue performance, of Wire Arc Additively Manufactured (WAAM) steel - a form of 3D printing various types of steel. There are many potential applications of additively manufactured materials, and their adoption for structural steel applications is still in its infancy. Farrokhi’s project will focus specifically on the fatigue behavior of WAAM specimens made of ER80S-Ni1 filler metals, which are higher strength (80 ksi yield) weld metals typically used in bridge applications due to their high toughness at low-temperature characteristics.

For this project, Farrokhi will test specimens with varying surface finishes and interpass temperatures to help determine the impact of the as-fabricated surface finish of WAAM steel as it pertains to fatigue performance. As such, this project will expose Farrokhi to many technical aspects of WAAM steel along with laboratory-based fatigue testing methods of metals and using collected lab data to draw certain conclusions about the material. In particular, she will complete component fatigue testing of WAAM steel specimens and correlate these results to an estimated fatigue life for different fatigue detail categories through regression analysis. The project will help shed further light on the behavior of WAAM in structural steel applications while providing an undergraduate student with exposure to an emerging technology they may very likely encounter in their professional career.

Student Name: Haixin Zhou
Faculty Sponsor: Hongxi Yin
Institute: Washington University in St. Louis

This project will study whether Wire-Arc Additive Manufacturing (WAAM) used in conjunction with topology optimization techniques can be effectively and efficiently used in creating new structural and architectural components that can provide more structural flexibility, optimization of material utilization, and enhanced aesthetic appeal. WAAM is a technique of 3D printing (also known as additive manufacturing) with steel that uses equipment capable of a high deposition rate of the metallic feedstock (welding wire) to ‘print’ three-dimensional objects of varying complexity. For this project, the research team will engage and collaborate with key industry stakeholders including Skidmore, Owings & Merrill (SOM) and Lincoln Electric in the design and manufacturing sectors, respectively. Through these research activities and collaborations, the team intends to develop a prototype steel connector that could be used in the Department of Energy’s Solar Decathalon competition for 2022. Ultimately, as WAAM is somewhat in its infancy for structural and architectural applications, this work has the potential to further demonstrate practical uses for the technology within the Architectural, Engineering, and Construction (AEC) industry.

Student Name: Aneesh Kakirde
Faculty Sponsor: Sougata Roy
Institute: Rutgers University

This project aims to address one of AISC’s current goals of increasing the speed of steel design, fabrication, and construction while also taking on the critical issue of updating America’s aging bridge inventory. The efforts of this Undergraduate Research Fellowship tie into a larger research project funded through the U.S. Department of Transportation (USDOT) entitled Cost-Effective Bridge Decks for Improved Durability and Extended Service Life, led by faculty sponsor Sougata Roy at Rutgers University. The primary goal of the larger USDOT project is to develop standardized designs for open rib steel orthotropic bridge decks for widespread use in short- to medium-span bridges. For  Undergraduate Research Fellowship, three-dimensional Finite Element Analysis (FEA) modeling techniques using the 3D commercially available program ABAQUS in conjunction with Python scripts will be utilized to conduct parametric studies of open ridge orthotropic bridge decks. Through the completion of these parametric studies, it will be possible to examine the 3D stress state of different designs and recommend standard designs developed and compared with experimental data from the larger USDOT project. This project will help the student achieve sophisticated engineering modeling and analysis techniques and will also support a larger endeavor that will greatly advance the state-of-the-art for short- and medium-span steel bridges.

Student Name: Edmund Elder
Faculty Sponsor: Hannah Blum
Institute: University of Wisconsin-Madison

This project will implement the use of AR in a steel fabrication environment through the use of the Microsoft Hololens headset in conjunction with software the research team will develop. The AR program to be developed will provide enhanced visualization of steel components and can be used to overlay dimensions and other features such as bolt holes or welds on pieces, perform QA/QC checks, and aid in fit-up of complex assemblages. Through the project, the student will be able to connect classroom concepts to real-world scenarios better and gain hands-on experience in a shop environment. The student will also collaborate with on-campus software developers to ensure the developed tools are practical to implement and straightforward to use.

The review panel believed this type of work could be of great value to fabricators by minimizing errors and possibly shortening fabrication time. Further, the reviewers felt this was a very compelling opportunity to assist in finishing a very promising project for the steel industry. In all, the reviewers were encouraged by the intended outcomes for this project and believe it has great potential to positively impact the steel fabrication industry.

Final Report

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Student Name: Edward Nelson
Faculty Sponsor: Pouria Bahmani
Institute: Milwaukee School of Engineering

This project will focus on determining the flexural and axial capacity of steel HSS end-plate connections through analytical study, finite element analysis, and experimental testing. The intent of the research is to help lead the development of innovative fastening systems and components that will enhance fabrication profitability and construction productivity while also improving structural performance. The intended outcome for the student is to be involved heavily with analytical studies and finite element simulations while also aiding in the laboratory with experimental testing. Through their involvement, they will gain valuable experience using common engineering analytical tools while also gaining practical experience in the lab environment.

The review panel thought this would be a very good and worthwhile project with results that could be of great value to the structural steel industry. They felt the provided work description was well-written and that the student had clear goals that were measurable and achievable. As a whole, this project will help advance the knowledge of the student and bring significant value to the structural steel industry.

Final Report

The Final Report for this project is pending due to some unforeseen circumstances with the undergraduate student.