Investigating local buckling in highly slender elliptical hollow sections through analysis of 3D-printed analogues

Tubular structural members with slender cross-sections are susceptible to failure through local buckling of their tube walls. Previous numerical studies of steel elliptical hollow sections in compression predicted the local buckling modes and the ultimate loads of particularly slender specimens, with the results used to calibrate design methods for slender elliptical sections. Although these numerical parametric studies were conducted across a wide slenderness range, it was only possible to validate the models against experimental results in the low slenderness range since commercially available steel EHS are intended to satisfy non-slender geometric limits prescribed by structural design codes. Such limitations to the experimental scope are circumvented in the present study through testing of highly slender specimens produced using additive manufacturing techniques. A total of eight specimens of various cross-sectional aspect ratios and tube wall thicknesses were fabricated at London South Bank University using additive manufacturing techniques, which were then tested in compression; the observed load-deflection behaviour, ultimate loads, longitudinal strains and failure modes are discussed. Through appropriate rescaling of relevant parameters, design predictions for the ultimate load of the 3D printed analogues are obtained using a design method intended for use with steel elliptical hollow sections. It is shown that the design predictions are safe-sided when compared to the present experimental results, with the accuracy generally increasing with aspect ratio and slenderness.