International Journal of Steel Structures 16(1): 41-50 (2016)

DOI 10.1007/s13296-016-3004-1
ISSN 1598-2351 (Print)
ISSN 2093-6311 (Online)
www.springer.com/journal/13296

Ultimate Shear Strength of Composite Welded

Steel-Aluminium Beam Subjected to Shear Load
Ahmed S. ELamary*
Faculty of Engineering, Civil Engineering Department, Al-Azhar University, Qena, Egypt
Faculty of Engineering, Civil Engineering Department, Taif University, Taif, KSA (Temporary)

Abstract
This paper describes a computationally designed process to determine the Ultimate Shear Resistance (USR) of composite
steel-aluminium beams subjected to shear load. Aluminium alloys are used in a variety of structural engineering applications
due to their high strength/weight ratio and durability. However, the strength of aluminium alloys is reduced near the weld due
to the heat of the welding process. The USR of several different cross-sectional shapes of composite beams were initially
computed using a proposed design equation. A consistent nonlinear 3-D finite element model using the ANSYS software
package was used to fulfil the performance criteria. The value of the USR obtained from the proposed design equation was
compared with the corresponding ultimate shear stress in the web panel obtained from the F.E. model. The outcome of the
proposed equation encouraged its use as a new design equation. This equation could accurately predict the USR.
Keywords: shear resistance, composite steel-aluminium, hoglund theory, beam

1. Introduction
Aluminium alloys can be used in different structural
engineering applications due to their high strength/weight
ratio and durability. These characteristics are of particular
significance in the design of lightweight and transportable
bridges, for which the ease and speed of construction, low
maintenance and long service life are important considerations.
Fabricated beams are normally designed to support vertical
loads over long spans, where high bending moments and
shearing forces are developed. In this paper, a new composite
built up section will be designed from aluminium web
and steel flanges.
The benefits of creating such a composite section are to
decrease the weight and cost of beams more and increase
the participation of aluminium alloys in structural applications.
Because the primary function of the flanges is to resist
axial compressive and tensile forces that arise from
bending action while the web resists the shear forces, this
paper will focus on the ultimate shear resistance that can
be carried by this type of section. The use of this type of
Received December 4, 2014; accepted November 27, 2015;
published online March 31, 2016
KSSC and Springer 2016
*Corresponding author
Tel: +201005054600, Fax: +20965210223
E-mail: zshamary@gmail.com

composite section will decrease the weight of the beam

and eliminate the effect of corrosion that may occur in the
web. However, the heat of welding is well known to
reduce the strength of aluminium alloys near the weld.
The heat-affected zone (HAZ) extends approximately
25 mm in all directions from the weld within the parent
metal (Amdahl et al., 2001). The ultimate shear resistance
of steel beams has been extensively studied, both experimentally and theoretically (Bradford, 1996; Lee et al.,
1996; Sulyok and Galambos, 1996; Lee and Yoo, 1998;
Davies and Griffith, 1999; Lee et al., 2008). The experimental studies of the USR of welded aluminium alloy
beams have indicated that failure generally occurs due to
the rupture of the welded web boundary during the development of a typical shear failure mechanism (Amdahl et al.,
2001; Evans and Burt, 1990; Justin, 2002; Ozturk and
Kilic, 2008). A more extensive experimental study was
conducted by Hoglund for aluminium plates welded together
with butt welds. The plates were of different sizes and
alloys. He divided them into two groups of welded profiles
that are distinguished according to heat-treated alloys.
The first group consisted of heat-treated alloys, and the
second group consisted of non-heat-treated alloys. The
non-heat-treated group is almost unaffected by welding.
The heat-treated group lost a significant amount of strength
in the heat-affected zone close to the weld. The proof
stress decreased up to 40-50%. This phenomenon arises
because the heat-treated alloy is heated at the weld. The

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Ahmed S. ELamary / International Journal of Steel Structures, 16(1), 41-50, 2016

crystal structure was changed, and the material lost its

strength (Amdahl et al., 2001). Effect of welding process
on Aluminum alloy studied by (Yan et al., 2012). A series
of fatigue test were carried out on scarfed lap joints (SLJ)
using in airfoil siding to explore the effect of structural
details, such as rows of rivets, lap angles, on its fatigue
performance. Finite element (FE) analysis was employed
to explore the effect of lap angle on load transfer and the
stress evolution around the rivet hole. At last, the fatigue
lives were predicted by nominal stress approach and critical
plane approach. One of the drawn conclusions was regarding
to scarfed lap joint which stated that, fatigue crack initiated
at hole bore in the lower sheet with a short distance from
faying surface. Crack initiation was induced by stress
concentration assisted by the fretting (Mohamed et al.,
2014). studied, a new simple first-order shear deformation
theory was presented for laminated composite plates.
Moreover, the number of unknowns of this theory was the
least one comparing with the traditional first-order and
the other higher-order shear deformation theories. Analytical
solutions of simply supported antisymmetric cross-ply
and angle-ply laminates are obtained and the results are
compared with the exact three-dimensional (3D) solutions
and those predicted by existing theories. It concluded
that, the proposed theory was accurate and simple in
solving the static bending and free vibration behaviors of
laminated composite plates. A new first-order shear
deformation beam theory based on neutral surface position
was developed for bending and free vibration analysis of
functionally graded beams by (Mohammed et al., 2013).
The proposed theory based on assumption that the inplane and transverse displacements consist of bending
and shear components, in which the bending components
do not contribute toward shear forces and, likewise, the
shear components do not contribute toward bending
moments. The results obtained using this new theory,
were found to be in excellent agreement with previous
studies. The proposed theory NFBT is not only accurate
but also efficient in predicting the static and dynamic
behavior of functionally graded beams. The capability of
finite element method to simulate the stress in steel
beams using ANSYS software program was studied by
(Soy, 2012). Stress and deflection behaviours of T-type
welding joint applied to HE200M steel beam and column
were investigated in finite element method (FEM) under
different distributed loads. Geometrical model was designed
as 3-dimensional solid in ANSYS software program.
Finite element analyses results and classical calculations
were compared each other and obtained as a logical
approach by favour of this study. Also, this study has
been emphasized that computer aided modelling can be
used together with the real applications. For the new
composite beam suggested in this paper, a computationally
aided process will be proposed via an equation based on
Hoglund theory. The equation can predict the ultimate
shear resistance of composite steel-aluminium beams

Figure 1. State of stress in web (Mohamed et al., 2014).

subjected to shear load. To verify the validation of the

proposed equation, a parametric analysis was conducted
using finite element models built to represent the variation
in the shapes of composite beams subjected to shear.

2. Shear Strength of Beam Web Panel using

Hoglund Theory
Hoglund rotating-stress-field theory is based on a
system of perpendicular bars in compression and tension.
This system is assumed to represent the web panel. In
pure shear, the absolute value of the principal membrane
stresses, 1 and 2, are the same in the absence of
buckling ( < cr). After reaching the buckling load (Vcr=
d*tw *cr), the web plate will buckle and the redistribution
of stresses begins. A remarkable increase in the tensile
stress, 1, due to increasing the applied load associated
with a slight increase in the compressive stress, 2, may
occur, as shown in Fig. 1.
The critical shear strength, cr , can be determined from
the classical stability theory for plates by (Timoshenko
and Gere, 1985):
2
- --t- 2
cr = K ----------------------yw
2
12 ( 1 ) d

(1)

The buckling coefficient, K, is obtained from the

following equation:
2
K = 5.35 + 4 d
--- , for b
--- > 1
b
d

(2)

2
b
K = 5.35 d
--- + 4 , for --- < 1
b
d

where E is the modulus of elasticity, and is Poissons

ratio. From Fig. 1
= 1 sin cos = 0.50 1 sin2

(3)

The direction of the tensile stresses is chosen to

maximise . When 1 is equal to the yield strength of the
web, yw , the following holds:
u 0.5 yw
3
---- = ------------------ = -----fv
fv
2

Ultimate Shear Strength of Composite Welded Steel-Aluminium Beam Subjected to Shear Load

Table 1. Reduction Factor v for shear buckling

w

Rigid end Post

(Aluminum)

Non-Rigid end Post

(Aluminum)

0.48
w < ---------

0.48 < 0.95

---------- w

0.48
---------w

0.48
---------w

w 0.95

1.32 ------------------------( 1.66 + w )

0.48
---------w

This theory is called the ideal tension field theory and

is valid only if the flanges are prevented from moving
towards each other by an external structure (Hglund,
1997). Furthermore, the slenderness parameter, w , is
introduced as
f
w = -----vcr

(4)

From Eq. (4), the ultimate strength, u =, can be

derived as a function of w as follows:
u 4 3
---- = ------fv w

1
1
1 --------4- ---------------24w 2 3w

(5)

(6)

The shear buckling capacity can be obtained from the

following:
V w = v yw d tw

(8)

2.1. Transversely stiffened web

Hoglund assumed that the shear force, which can be
carried by the web panel, can be represented by a system
of perpendicular bars in compression and tension, as
shown in Fig. 2(a). The transverse stiffeners welded to
the web can affect the behaviour and strength of a beam
subjected to shear by preventing the web from out-ofplane deflections and preventing the flanges from approaching
each other at the failure stage. Four hinges denoted E, H,
G, and K, from the top and bottom flanges are shown in
Fig. 2(b). Points E, H, K, and G in this figure represent
the tension stress field. The flange shear force, Vf, which
is transmitted by the tension stress field, is obtained from
the equation of equilibrium of the flanges as follows:
4 Z
Vf = ------------------yfc

(9)

The ultimate shear resistance of the beam, Vu , is the

sum of the shear resistance of the web, Vw , and the shear
resistance due to the contribution of the flanges, Vf.:
Vu =Vw +Vf

(10)

A distance, c, is estimated for aluminium beams

obtained by (Hoglund, 1997) as follows:

for w 1.00, where if w 2.5 leads to

u 1.32
---- ---------fv w

The reduced value, v, is related to the scatter in test

results as a result of initial imperfections and plastic
buckling (Hoglund, 1997).
uw
= 0.40 + 0.20 ------yw

yw
for =45o where fv = ------3

43

(7)

Table 1 shows the values of v, which can be defined as

the shear buckling reduction factor:

4.4 bf tf yf
------------------------------c = 0.08 +
b
2

tw d yw

(11)

Where equation (11) will take the following form for

steel beams, as stated by (Hoglund, 1997):

1.6 bf tf yf
c = 0.25 + ------------------------------ b
2

tw d yw

Figure 2. Model of web in post buckling range.

(12)

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Ahmed S. ELamary / International Journal of Steel Structures, 16(1), 41-50, 2016

Figure 3. Bio-metal to weld Aluminum with Steel (taken

in EGPTYALUM Factory-Upper Egypt).

3. Composite Aluminium Steel Beam

3.1. Fabrications
A new production process consists of stacking two
different materials -Aluminium and Steel- together to
generate a special weld thread can be used to weld the
aluminium web with steel flanges in composite beam, as
illustrated in Fig. 3. Bio-metal can be used as a weld
thread during the process of welding aluminium and steel.
In this case, the Bio-metal will be implemented by using
the aluminium side to be welded with the aluminium
web, while the steel side can be welded with the steel
flanges.
3.2. Finite element model
Numerical analyses were carried out using the nonlinear finite element software package ANSYS. The analysis
was based on the 4-node shell element SHELL43 available
in ANSYS, which was adopted for the discretisation of
both the web and flanges. Figure 4 shows the boundary
conditions and mesh of the developed FE model. The
material properties of the steel and aluminium are specified
using the elastic and metal plasticity with plastic options.
Newtons iterative technique was used to analyse the nonlinear response of the model under loading. The analysis
process was controlled by material yielding, which was
defined by the von Mises yield and shear stress functions.
Further details of the formulation and computations in the
analysis can be found in the ANSYS, Inc. (2005). The

boundary conditions of the FE model for the local translations,

x, y, and z, and the respective rotations, x , y, and z are
shown in the brackets in Fig. 4(a). One degree of freedom
represents a fixed scenario, while 0 represents a free
scenario. Figure 4(b) illustrates the beam dimensions and
material properties. In the analysis, the web plate is assumed
to have an initial out of plane displacement compatible
with the governing buckling mode with maximum amplitude
of d/4000. The author previously calibrated the capability
of ANSYS to address the steel beams subjected to shear
by comparing the performed finite element model with
the test results on restrained steel beams at large deflections
obtained by (Vimonsatit et al., 2007a,b). The model was
built using the four-node quadrilateral plate/shell elements,
SHELL43, available in ANSYS, Inc. (2005). The fournode element was formulated by treating the plate as a
three-dimensional continuum.
The maximum web shear stress can be calculated from
the web yield stress divided by the square root of three;
this shear stress will be affected and increased gradually
at the shear centre point. The shear centre is defined as
the point at which the shearing force applied such that the
material bends without twisting. The shear centre depends
mainly on the geometric properties of the section; for a
beam with two axes of symmetry, the shear centre will
fall at the intersection of the axes. To study the distribution
of shear stress through the web panel, especially in heataffected zone (HAZ), a finite element model for composite
beams made of aluminium web and steel flanges was
developed, as shown in Fig. 4(b). Figure 5 shows the
distribution of shear stress through the different steps of
applied load. The distribution of web shear stress at 50%
of the maximum load shown in Fig. 5(a) is maximised at
83.7 N/mm2 at the web mid-height (shear centre) and
decreases gradually when moving towards the flanges. At
this stage of loading, the shear stress at the top and
bottom boundaries of the web equal 30% of the maximum
shear stress. By increasing the load to 95% of the
maximum load, the shear stress at mid-height increases to
99.8% of the ultimate stress, and the top and bottom

Figure 4. Shear panel boundary conditions and finite element model.

Ultimate Shear Strength of Composite Welded Steel-Aluminium Beam Subjected to Shear Load

45

Figure 5. Shear stress distributions.

Figure 6. Heat treatment effect on Youngs modulus of aluminum alloy (Amdahl et al., 2001).

boundary stress reach 60% of the ultimate stress, as

shown in Fig. 5(b).
Because the aluminium crystal structure is changed, the
material loses its strength due to the heat-treatment at the
weld, which can lead to decreases in the yield stress up to
40-50% (Amdahl et al., 2001). According to various
sources, the effect of heat treatment on Youngs modulus
of the aluminium alloy only ranges from 0-2% (Amdahl
et al., 2001; Justin, 2002). This effect was confirmed by
(Amdahl et al., 2001) they tested Aluminium plated
structures at elevated temperatures under pure shear, the
results shown in Fig. 6(a) and 6(b).
The effect of HAZ can be simulated by attributing reduced
stress values to the elements adjacent to the welds. The
model was built using the four-node quadrilateral plate/
shell elements, SHELL43, available in ANSYS, Inc. (2005).
The four-node element was formulated by treating the
plate as a three-dimensional continuum. The convergence
analysis of a steel beam is satisfactorily accurate when the
elements were 2525 mm for flanges, web, and transverse
stiffeners (Elamary, 2009). The difference between the
exact solution and the buckling stress obtained from the
finite element analysis was less than 2%. Therefore, this
type of mesh refinement was deemed acceptable for the
nonlinear analysis. As stated by (Amdahl et al., 2001) the

heat-affected zone (HAZ) extends within the parent metal

approximately 25 mm in all directions from the weld.
Consequently, the stresses of the first and last two rows
from web elements differ from those of the remaining
web elements.

3.3. Modelling of composite Aluminium-Steel beam

The finite element model was based on the 4-node shell
element SHELL43, which was adopted for the discretisation
of both aluminium web and steel flanges. Figure 7 shows
the mesh of the developed finite element model and the
areas of HAZ. Satisfactory accuracy was obtained for
2525 mm elements size in the flanges, web plate and
transverse stiffeners. In this model the number of nodes
ranged from 1105 (G1) to 1945 (G4) where the number
of elements ranged from 960 to 1728 respectively. The
assumed material model was a continuous true stressstrain relationship. A stress-resultant material model was
adopted for the shell element, which obeys a linear
elastic-linear hardening law.
The effect of the HAZ is simulated by attributing
reduced stress values to elements adjacent to the welds.
For the first and the last two rows from the web elements,
the yield stress is decreased by 40%, while the modulus
of elasticity remains the same. Because the out-of-plane

46

Ahmed S. ELamary / International Journal of Steel Structures, 16(1), 41-50, 2016

in material strength due to welding, the value of v is

reduced relating to the scatter in the test results. The
buckling capacity can be obtained from the following:
Vw = v yw d tw
The flange shear force, Vf , which is transmitted by the
tension stress field, is obtained from the equation of the
equilibrium of the steel flanges portion, c:
4 Z
Vf = ------------------yfc
Figure 7. Finite element model of composite AluminumSteel beam.

deformations do not occur in perfectly flat plates under

pure shear, a small initial out of plane deflection compatible
with the governing buckling mode is introduced using
maximum amplitude less than d/4000. Based on ICE manual
of bridge engineering (Gerard and Hewson, 2008); which
stated that For a slender plate, the behaviour is dominated
by the out-of-plane response with buckling and hence
elastic behaviour being dominant. As in-plane stress levels
are relatively low and yield occurs as an out-of-plane
extreme fibre phenomenon particularly concentrated at
the central zone of the plate, residual stresses are of little
importance. While geometric imperfections will affect the
behavior and reduce the plate in-plane stiffness, because
of the post-buckling stability, the sensitivity of the collapse
behaviour to imperfection levels will be modest and the
ultimate load will be dictated by the interaction between
buckling defections and out-of-plane yielding, consequently
this low value to cover also the effect of residual stresses.
The material properties of steel and aluminium are specified
as shown in Fig. 4(b).

3.4. Proposed design equation

The shear resistance of the beam, Vu , is the sum of the
shear resistance of the web, Vw , and the shear resistance
contributed by the flanges, Vf . To allow for the reduction

(13)

Finally, the proposed equation can be written as

follows:
4 Z
VU = v yw d t w + ------------------yfc

(14)

where v is given in table (1)

1.6 bf tf yf
and c = 0.25 + ------------------------------b.

tw d yw
A comparative numerical analysis was carried out to
test the validity and assess the accuracy of the suggested
equation in this study. The ultimate shear resistance of
composite aluminium-steel beams of various cross-sectional
areas is obtained by applying the proposed equation. The
dimensions and properties of the web with 270 MPa yield
stress and 70,000 MPa modulus of elasticity are listed in
Table 2. The dimensions and properties of the flanges
were bf =300 mm, tf =8 mm, yf =360 MPa, E=2105 MPa.
To verify the results obtained from the proposed formula,
a consistent nonlinear 3-D finite element approach adopted
using the ANSYS package. The finite element model
executed for each beam using the dimensions and properties
stated in Table 2 was subjected to the ultimate shear load
obtained from the formula. Figure 8(a)-8(b), show the
buckling mode of a model with b/d =1.5 at the end of the
analysis. By applying a shear load equal the value obtained

Figure 8. Finite element model and buckling shape of beam under studying.

47

Ultimate Shear Strength of Composite Welded Steel-Aluminium Beam Subjected to Shear Load

Figure 9. Beam G1 with tw ranged from 3 to 5 mm.

Table 2. Details and results of analyzed composite beams
F.E.M.

WEB
Beam
reference/
Figure

Total shear
load
achieved
(kN)

F.E.M.

141.7
220.5
263.6
308.6

138.86
218.5
261
307.1

151.7
155.1
155.8
155.7

97
99
100
100

0.13

1.25

132.6
208.2
249.7
293.2

130
203
247.21
290.27

154.8
155.1
155.4
155.8

99
99
100
100

0.13

1.5

127
200.6
241.1
283.7

123.2
196.59
238.69
279.45

155.1
155.2
155.8
155.6

99
99
100
100

0.135

120.6

118.6

192

d
mm

b
mm

tw
mm

G1
Fig. 9

600
600
600
600

600
600
600
600

3
4
4.5
5

G2
Fig. 10

600
600
600
600

750
750
750
750

3
4
4.5
5

G3
Fig. 11

600
600
600
600

900
900
900
900

3
4
4.5
5

600

1200

600

1200

G4
Fig. 12

VU kN
proposed
equation

Ultimate web shear

N/mm2

Aspect
Ratio

% from Initial out of

theoretical plane (mm)

yw
fv = ------3

154.4
100
Global Buckling at 40%
from applied load

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Ahmed S. ELamary / International Journal of Steel Structures, 16(1), 41-50, 2016

Figure 10. Beam G2 with tw ranged from 3 to 5 mm.

Figure 11. Beam G3 with tw ranged from 3 to 5 mm.

Ultimate Shear Strength of Composite Welded Steel-Aluminium Beam Subjected to Shear Load

Figure 12. Beam G4 with tw 3 mm.

from the proposed equation, ultimate web shear stress for

each beam with the percentage of variances from
theoretical web ultimate shear obtained from Eq. 5 was
listed in Table 2 and plotted from Figs. 9 to 11.
By increasing the web thickness to 4 mm while not
changing the depth, the ultimate shear load that can be
resisted will be increased by 58% according to the
proposed equation. The ultimate finite model could not
reach 40% of the total applied load, and earlier buckling
occurred due to small values of the initial out of plane
displacement (less than d/4000). This leads to that, the
proposed equation is not applicable when panel aspect
ratio equal 2, and this type of beam can be considered as
a beam with a long web panel, where the out of plane
deformations should be d/10000, as stated in (Sung et al.,
2008).

4. Summary and Conclusions

In this study, a new composite beam was suggested that
consists of steel flanges and an aluminium web. Based on
Hoglund theory, a computationally aided design process
was developed to determine the ultimate shear resistance
of composite steel-aluminium beams. To verify the validation
of the proposed equation, a parametric analysis was
conducted using finite element models using different
web panel aspect ratio to represent the variation in the
shapes of composite beams and obtained the maximum
shear stress that can be sustain by web panel. The
following can be concluded from this study:
(1) The proposed equation can be used to predict the
ultimate shear resistance of composite steel-aluminium
beams that feature intermediate transverse stiffeners for
web panel aspect ratios, b/d (width/depth of web panel),
between 1 and 1.5.
(2) The finite element model can predict the ultimate
shear resistance of a composite aluminium steel panel
with a notably high degree of accuracy.
(3) The heat-affected zone (HAZ) can be simulated
using finite element analysis by decreasing the strength of
aluminium elements by 40%.

49

Nomenclature
b : Width of web panel
bf : Flange width
c : Distance between flange plastic hinges
d : Depth of web panel
E : Modulus of elasticity
fv : Critical shear stress
k : Buckling coefficient
tw : Web thickness
tf : Flange thickness
Vcr : Critical shear force
Vf : Flange shear force
Vu : Ultimate shear force of composite aluminium steel
beam
Vw : Web shear force
v : Shear buckling reduction factor
: Angle of principle membrane stresses inclination
1 : First principle membrane stress
uw : Web ultimate stress
yf : Flange yield stress
yw : Web yield stress
: Initial imperfection and plastic buckling effect
factor
: Shear stress
cr : Critical shear stress
u : Ultimate shear stress
yw : Shear stress at yield
: Poissons ratio
w : Slenderness parameter

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