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•Conducted tensile tests on CFRP-strengthened butt-welded ultra-high strength steel (UHSS)•Performed FE analysis of CFRP-strengthened butt-welded UHSS under tension.•Compared with results of CFRP-strengthened mild steel under tension.•Compared with results with high frequency mechanical impact treatment and TIG-dressing.
Due to the softening at the heat-affected zone (HAZ) in ultra-high strength steels (UHSS), the mechanical properties can deteriorate depending on the steels’ grade, welding heat input, and its associated cooling rate. Hence, a design based on the properties of the base material (BM) may not be appropriate, and there is a need to retain the lost properties of the weldment. This study presents an effort to strengthen butt-welded UHSSs using ultra-high modulus (UHM) carbon fiber reinforced polymer (CFRP) plates. Although the rehabilitation and strengthening of steel structures using CFRPs have been available during the last two decades, they have not been used to strengthen higher grades of steel such as UHSSs. For this aim, a series of tensile tests were carried out on butt-welded UHSSs strengthened with adhesively bonded UHM CFRP plates on both sides of the weldment. Two welding processes, i.e. the gas metal arc welding (GMAW) and laser welding, were implemented separately to join the plates. Microhardness measurements and tensile tests were carried out for the experimental part, as well as finite element (FE) analysis of the joints. The results were also compared with other available methods, i.e. high-frequency mechanical impact (HFMI) treatment and TIG-dressing (tungsten inert gas) of the weld toe that are commonly used to increase the fatigue life of UHSS joints. It was found that CFRP strengthening can not only retain the lost properties of the weldment but can also increase the joint strength up to 32% compared to the BM, and a considerable 50% higher stiffness. In contrast, the other methods (HFMI and TIG-dressing) had no impact on the tensile characteristics of the weldments.