Additive Manufacturing of Steel-Reinforced Concrete by Combination of Selective Paste Intrusion and Wire Arc Additive Manufacturing: Impact of Heat Generated by WAAM on Bond Behavior of the Reinforcement (Dataset)

This dataset accompanies a study on integrating Wire Arc Additive Manufacturing (WAAM) into the Selective Paste Intrusion (SPI) process for fabricating steel-reinforced concrete with complex geometries. The work quantifies how the localized, process-integrated heat that a WAAM reinforcement segment transfers into the surrounding fresh cement paste affects the bond between steel and concrete. Pull-out tests according to RILEM RC6 were carried out on WAAM reinforcement bars (nominal diameter 12 mm, produced by the Cold Metal Transfer cycle step process) that were heated to 20 °C (ambient reference), 60 °C, 80 °C, and 200 °C and held for 18 min before the surrounding concrete cured. The reference at 20 °C reached the highest bond stress at every measured displacement, with a mean maximum bond stress of 19.67 N/mm². Moderate thermal exposure at 60 °C and 80 °C reduced the maximum bond stress to 17.08 and 17.00 N/mm², whereas heating to 200 °C reduced it to 13.99 N/mm². Complementary X-ray diffraction (XRD), thermogravimetric analysis (TGA), and mercury intrusion porosimetry (MIP) relate the mechanical response to temperature-dependent changes in hydration, carbonation, and pore structure of the interfacial transition zone. The dataset contains the raw and processed measurement data behind the figures and tables of the publication. It comprises pull-out raw data for the four temperature series with three specimens each, the concrete strength test report for the companion prisms cast per DIN EN 196-1, TGA raw data, MIP raw data, XRD diffractograms including the proprietary Bruker raw format, and the corresponding evaluation spreadsheets. The final microstructure figures (XRD, TGA, MIP) and additional MIP plots are included as PNG images. Technical notes: tabular data are provided as Microsoft Excel workbooks (.xlsx and legacy .xls) and comma-separated text (.csv). Reports and instrument printouts are PDF files, diffractograms and mass-loss logs are plain text (.txt), and the XRD raw measurements are additionally stored in the Bruker format (.brml, .pro, .raw). Figures are PNG images. Spreadsheets open in Microsoft Excel or a compatible application. CSV and TXT files can be read with any spreadsheet software or a scripting environment such as Python with pandas. The Bruker .brml files require the manufacturer software (DIFFRAC.SUITE) or a compatible reader. Methods in brief: the concrete used a water-to-cement ratio of 0.40 with ordinary Portland cement (strength class 42.5 N), quartz sand (1.0 to 2.2 mm), and a polycarboxylate-ether superplasticizer, matching the paste-to-aggregate volume ratio of the SPI particle bed (42 vol.% cement paste and 58 vol.% aggregate). Cubic specimens with an edge length of 200 mm held a centrally placed WAAM bar with an embedded bond length of 60 mm (5 times the bar diameter). A cartridge heater inserted into a drilled core hole applied the defined temperature, controlled by a Shinko GCS controller in on/off mode. Pull-out tests ran on a Zwick Z600 machine at a load rate of 72 N/s with slip recorded at the unloaded bar end. XRD used a Bruker D8 ADVANCE 145 (CuKα), TGA a Netzsch STA 449 F3 Jupiter (10 K/min, nitrogen), and MIP a Microtrac BELPORE LP and HP system. This dataset is a supplement to the peer-reviewed article published in Materials (MDPI) 2025, volume 18, article 5455 (DOI 10.3390/ma18235455). It is intended as a new version of the existing Zenodo record 16562375, adding the microstructural measurement data (TGA, MIP, XRD) behind Figures 7 to 9 that were not part of the earlier record. This research was funded by the Deutsche Forschungsgemeinschaft (DFG) within the collaborative research centre TRR277 Additive Manufacturing in Construction (AMC), project number 414265976.