Fatigue Performance Research and Structural Optimization of Steel–AAUHPC Composite Bridge Deck

To investigate the fatigue performance of a novel green low-carbon steel–AAUHPC (Alkali Activated Ultra-high Performance Concrete, AAUHPC) composite bridge deck and achieve its structural optimization, this paper proposes a steel–AAUHPC composite bridge deck structure featuring double-sided welding of U-shaped ribs. Firstly, the numerical model of a symmetrical composite bridge deck is established by ABAQUS finite element software. The stress response of key fatigue structural details is analyzed, and the fatigue life is evaluated based on the S-N curve method. At the same time, the calculation results are compared with the orthotropic steel bridge deck and the steel–UHPC composite bridge deck. Secondly, the CCD method and RSM method are used to construct a mathematical regression model with the structural weight W per unit area and the fatigue stress amplitude of key details as the target. Finally, NSGA-III is used to optimize structural parameters such as AAUHPC thickness, top plate thickness, diaphragm thickness and spacing to obtain the Pareto-optimal solution set. The results show that the AAUHPC material has both environmental protection and excellent mechanical properties, and its compressive and splitting tensile strength is significantly higher than that of ordinary concrete, which is close to the UHPC level. The steel–AAUHPC composite bridge deck can significantly improve the fatigue performance of the orthotropic steel bridge deck. After laying the AAUHPC layer, the stress amplitude of each fatigue detail decreases, and the C1 detail decreases by up to 69.4%. Except for the C6 detail, the rest of the structural details meet the infinite-life design criteria, and the overall improvement effect is comparable to that of the steel–UHPC composite bridge deck. The constructed response surface model has good prediction accuracy. The optimization results show that the fatigue stress amplitude and the structural weight W are mutually restricted. Among the 15 sets of Pareto-optimal solutions obtained, solution U8 achieves weight minimization under the premise of satisfying the infinite-fatigue-life criterion. The optimal parameter combination is: AAUHPC thickness of 40 mm, top plate thickness of 10 mm, diaphragm thickness of 16 mm, and diaphragm spacing of 2400 mm. The research results can provide a theoretical basis for the fatigue design and engineering application of a new green steel–AAUHPC composite bridge deck.