Materials, Volume 17, Issue 3 (February-1 2024) – 235 articles

Precision manufacturing requirements are the key to ensuring the quality and reliability of biomedical implants. The powder bed fusion (PBF) technique offers a promising solution, enabling the creation of complex, patient-specific implants with a high degree of precision. This technology is revolutionizing the biomedical industry, paving the way for a new era of personalized medicine. This review explores and details powder bed fusion 3D printing and its application in the biomedical field. It begins with an introduction to the powder bed fusion 3D-printing technology and its various classifications. Later, it analyzes the numerous fields in which powder bed fusion 3D printing has been successfully deployed where precision components are required, including the fabrication of personalized implants and scaffolds for tissue engineering. This review also discusses the potential advantages and limitations for using the powder bed fusion 3D-printing technology in terms of precision, customization, and cost effectiveness. In addition, it highlights the current challenges and prospects of the powder bed fusion 3D-printing technology. This work offers valuable insights for researchers engaged in the field, aiming to contribute to the advancement of the powder bed fusion 3D-printing technology in the context of precision manufacturing for biomedical applications. Full article

Poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) is a biobased and biodegradable polymer. This polymer is considered promising, but it is also rather expensive. The objective of this study was to compound PHBV with three different organic fillers considered waste: human hair waste (HHW), sawdust (SD) and chitin from shrimp shells. Thus, the cost of the biopolymer is reduced, and, at the same time, waste materials are valorised into something useful. The composites prepared were characterised by differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), tensile strength and scanning electron micrograph (SEM). Tests showed that chitin and HHW did not have a reinforcing effect on tensile strength while the SD increased the tensile strength at break to a certain degree. The biodegradation of the different composites was evaluated by a soil burial test for five months. The gravimetric test showed that neat PHBV was moderately degraded (about 5% weight loss) while reinforcing the polymer with organic waste clearly improved the biodegradation. The strongest biodegradation was achieved when the biopolymer was compounded with HHW (35% weight loss). The strong biodegradation of HHW was further demonstrated by characterisation by Fourier-transform infrared spectroscopy (FTIR) and solid-state nuclear magnetic resonance (NMR). Characterisation by SEM showed that the surfaces of the biodegraded samples were eroded. Full article

One fascinating concept for enhancing the durability and lifespan of concrete buildings involves the use of self-healing concrete. This study focuses on the effect of crystalline admixtures and coatings on various properties of self-healing concrete and provides a comparison with traditional concrete. Four different concrete mixtures were prepared to assess their effectiveness in bridging crack openings, their flexural and compressive strengths, and water absorption. Various testing methods, including destructive, semi-destructive, and non-destructive tests, were used in this research. The capacity of the mixes to repair themselves was assessed on the destroyed and semi-destroyed test specimens using crack-healing and microstructure testing. Additionally, all mixtures were also subjected to the slump cone test and air content test in order to investigate the characteristics of the concrete in its fresh state. The findings demonstrate that crystalline coating and admixture combinations have significant potential for healing concrete. The compressive and bending strengths of self-healing concrete mixtures were shown to be slightly higher compared to traditional concrete when the additive dose was increased. Self-healing concrete mixtures also exhibited much lower water absorption, a tightly packed and improved microstructure, and signs of healed gaps, all of which indicate greater durability. Full article

In this study, tea waste was used as a raw material, and TBC (tea waste biochar) was prepared by pyrolysis at 700 °C. La(NO₃)₃·6H₂O was used as the modifier to optimize one-way modification; the orthogonal experiment was undertaken to determine the optimal preparation conditions; and La-TBC (lanthanum-modified biochar) was obtained. The key factors for the adsorption of fluoride by La-TBC were investigated by means of batch adsorption experiments, and kinetics and isothermal adsorption experiments were carried out on the adsorption of fluoride in geothermal hot spring water. The adsorption mechanism of fluoride by La-TBC was analyzed via characterization methods such as SEM-EDS (Scanning Electron Microscope and Energy Dispersive Spectrometer), BET (Brunauer–Emmett–Teller), FTIR (Fourier transform infrared), XRD (X-ray diffraction), and so on. The results show that La-TBC had the best adsorption effect on fluoride at pH 7. The process of adsorption of fluoride follows the pseudo-second-order kinetics and Langmuir isothermal model, and the maximum theoretical adsorption quantity was 47.47 mg/g at 80 °C, while the removal rate of fluoride from the actual geothermal hot spring water reached more than 95%. The adsorption process was dominated by the monolayer adsorption of chemicals, and the mechanisms mainly include pore filling, ion exchange, and electrostatic interaction. Full article

Conveyors play a very important role in modern manufacturing processes, and one of the most popular types is the belt conveyor. The main elements of a conveyor include a conveyor belt, roller sets, a supporting frame and a drive and control system. The reliable operation of the conveyor depends on the strength and durability of individual elements (especially the belt). Conveyor belts are made from various materials and have received a lot of attention in the scientific and research community. This article presents tests of the strength of the rubber belt material and its damage under load. The belt consists of two internal layers covered with a PVC coating on the outside, and the nominal belt thickness was 2 mm. In the experiment, various configurations of longitudinal and transverse damage were verified, and statistical methods were used to analyze the results. The obtained test results provided a new understanding of the propagation of conveyor belt damage and helped to improve the strain gauge-based monitoring system. Full article

Self-healing cementitious materials containing microcapsules filled with healing agents can autonomously seal cracks and restore structural integrity. However, optimising the microcapsule mechanical properties to survive concrete mixing whilst still rupturing at the cracked interface to release the healing agent remains challenging. This study develops an integrated numerical modelling and machine learning approach for tailoring acrylate-based microcapsules for triggering within cementitious matrices. Microfluidics is first utilised to produce microcapsules with systematically varied shell thickness, strength, and cement compatibility. The capsules are characterised and simulated using a continuum damage mechanics model that is able to simulate cracking. A parametric study investigates the key microcapsule and interfacial properties governing shell rupture versus matrix failure. The simulation results are used to train an artificial neural network to rapidly predict the triggering behaviour based on capsule properties. The machine learning model produces design curves relating the microcapsule strength, toughness, and interfacial bond to its propensity for fracture. By combining advanced simulations and data science, the framework connects tailored microcapsule properties to their intended performance in complex cementitious environments for more robust self-healing concrete systems. Full article

The convolution of two physical entities, denoted as f and g, delineates the manner in which one entity undergoes modification in response to the other. This transformative process is mathematically represented by the expression f ⨂ g, symbolizing the convolution of the two entities in a resultant function h. Frequently, it becomes imperative to comprehend the magnitude of the induced modifications. From the derived function h, a crucial step involves the separation of the two original signals, a process commonly referred to as deconvolution. Various techniques have been proposed to facilitate the calculation of the deconvolution, with one notable approach originating in 1931 by van Cittert. The algorithm, based on an iterative method, has been scrutinized over time, notably by Bracewell and, more recently, by Jansson. This work represents the current state-of-the-art, focusing specifically on the analysis of Auger spectra obtained through XPS. Emphasis is placed on delineating the procedural aspects of the analysis, and the algorithm utilized in the open-source software RxpsG is comprehensively described. Full article

Surface features are crucial for assessing welding quality because they serve as an intuitive depiction of the quality of the joint and have a major influence on welding strength. According to the characteristics of the refill friction stir spot welding (RFSSW) process and an analysis of the surface-state and internal morphology of RFSSW joints, a method of predicting the mechanical properties of RFSSW joints based on surface-state characteristics was proposed. In this paper, a laser-ranging sensor was used to characterize the surface state of RFSSW joints, and parametric characterization methods of the surface-state features of RFSSW joints were proposed. On this basis, a support vector machine was used to predict and analyze the fracture mode of RFSSW joints. The accuracy of the analysis of the test samples reached 95.8%. This paper provides a more efficient and convenient new method for the quality evaluation of RFSSW joints. Full article

Unsaturated polyester resin (UPR) with excellent flame retardant is mainly obtained by adding large amounts of flame retardants, usually at the expense of mechanical properties. In this work, a reactive flame retardant containing phosphorus and nitrogen (DOPO-N) was successfully synthesized and incorporated in UPR as a crosslinker. The mechanical and flame-retardant properties of UPR composites were enhanced. UPR/30DOPO-N passed a UL-94 V-1 rating with a limiting oxygen index (LOI) of 30.8%. The tensile strength of UPR/30DOPO-N increased by 24.4%. On this basis, a small amount of modified HNTs (VHNTs) was added to further improve the flame-retardant properties of the composite. With the introduction of 3 wt% VHNTs, the composite passed the UL-94 V-0 rating. The peak of heat release rate (PHRR) and total heat release (THR) of it decreased by 60.7% and 48.3%, respectively. Moreover, the detailed flame-retarding mechanism of DOPO-N and VHNTs was investigated by thermogravimetric infrared spectroscopy (TG-IR), Raman spectra, and X-ray photoelectron spectroscopy (XPS). It was found that DOPO-N played a role in quenching the flame in the gas phase and cooperated with VHNTs to enhance the barrier effect in the condensed phase. Full article

The article presents research results regarding the possibility of modifying pre-stressed concrete railway sleepers to improve their durability. The cracks that appear in these elements are one of the reasons for shortening the period of safe use. They do not have a significant impact on the load-bearing capacity of these elements, but on their durability. The resulting scratches become an easy way for the external environment to migrate inside the element, including the reinforcement area. Despite efforts to eliminate the possibility of cracking, this phenomenon still occurs in railway sleepers. In order to reduce the negative effects of cracking the cement matrix, a technology for modifying a prefabricated concrete element with resin-filled tubes towards its autonomous self-healing was developed and tested. The tests were divided into three stages, including laboratory tests carried out on cement mortar beams, semi-technical tests carried out on reinforced concrete beams, and industrial tests carried out on pre-stressed concrete and prefabricated railway sleepers. All research conducted on a laboratory and semi-technical scale, preceding the target stage, was intended to ultimately enable the development of tube application technology on an industrial scale while verifying the effectiveness of self-healing at the laboratory level. The use of self-healing cementitious materials potentially reduces the negative effects of cracking railway sleepers, as shown by observations conducted during the research. Full article

In this contribution, the development of a 3D-printed soft actuator integrated with shape memory alloys (SMA) wires capable of bending in two directions is presented. This work discusses the design, manufacturing, modeling, simulation, and feedback control of the actuator. The SMA wires are encased in Polytetrafluoroethylene (PTFE) tubes and then integrated into the 3D-printed matrix made of thermoplastic polyurethane (TPU). To measure and control the deformation angle of the soft actuator, a computer vision system was implemented. Based on the experimental results, a mathematical model was developed using the system identification method and simulated to describe the dynamics of the actuator, contributing to the design of a controller. However, achieving precise control of the deformation angle in systems actuated by SMA wires is challenging due to their inherent nonlinearities and hysteretic behavior. A proportional-integral (PI) controller was designed to address this challenge, and its effectiveness was validated through real experiments. Full article

The stress distribution in prestressed filament wound components plays a crucial role in determining the quality of these components during their operational lifespan. This article proposes a physical model to analyze the stress and deformation of prestressed wound composite components with arch-shaped sections. Drawing upon the principles of beam theory, we delve into the analysis of prestressed wound components with metal liners featuring arch-shaped sections. Our investigation revealed a noteworthy phenomenon termed the “additional bending moment effect” within prestressed wound components with arch-shaped sections. Furthermore, this study establishes a relationship between this additional bending moment and the external pressure. In addition, a 3D finite element (FE) model for prestressed wound components with arch-shaped sections incorporating metal liners was developed. The model’s accuracy was validated through a comparison with prestressed wound experiments, showcasing an error margin of less than 2%. In comparison with prestressed wound components with circular cross-sections under identical load and dimensional parameters, it was observed that prestressed wound components with arch-shaped sections exhibit stress distributions in the arc segments akin to their circular counterparts, with differences not exceeding 5%. Notably, when the ratio of the straight segment length to the inner diameter of the arc segment inner is less than 4, the deformation on the symmetric plane of the arc segment in an arch-shaped component can be effectively considered as the summation of deformations in equivalent-sized arc and straight segments under identical loading conditions. This yields an equivalent physical model and a streamlined analysis and design methodology for describing the deformation characteristics of prestressed wound components with arch-shaped sections. Full article

A method of internal pressure–temperature coupling analysis for the thermal decomposition of GFRP composites under high-temperature conditions was established, which incorporates coupled calculations of heat transfer equations, the Arrhenius equation, Darcy’s law, and the ideal gas state equation. Using the overlapping mesh method, the coupling calculation of temperature and internal pressure is realized based on the UMATHT and USDFLD user subroutines developed. Specifically, two user subroutines, UMATHT-1 and UMATHT-2, are used to define the heat transfer equation and gas diffusion equation separately. Numerical simulations are conducted to simulate the polymers’ thermal decomposition in high-temperature environments. For glass fiber/vinyl ester composites and glass fiber/phenolic composites, the predicted temperature and pressure values are in good agreement with experimental measurements, and porosity and permeability are then analyzed. Due to the accumulation of thermal decomposition gases, inter-pressure within the material surged and reached a peak value. After that, it began to decrease, but the factors affecting the pressure decrease vary at different positions. Specifically, the pressure closest to the heating surface is influenced by the combined effects of decomposition rate, permeability, and porosity, while the pressure far away from the heating surface is only affected by the initial permeability. The pressure in the intermediate region may be influenced by both increased porosity and initial permeability. Full article

We investigated the screw hole position of a board level reliability (BLR) test board to improve the fatigue reliability of solder joints under thermal cycling and random vibration. We developed a finite element model of a BLR test board and derived the plastic strain energy density and 1-sigma stress, which are the main parameters influencing the fatigue life of solder joints under thermal cycling and random vibration, respectively. We analyzed the correlation between the screw hole position and the main parameters of the fatigue life through sensitivity analysis. By performing multi-objective optimization, we determined the screw hole position that maximizes the fatigue life of solder joints under thermal cycling and random vibration. With the optimal screw hole position, the fatigue life significantly increased under thermal cycling and random vibration compared to the BLR test board with the initial screw hole position. Full article

(Si/graphite)@C and (Si/graphite/graphene)@C were synthesized by coating asphalt-cracked carbon on the surface of a Si-based precursor by spray drying, followed by heat treatment at 1000 °C under vacuum for 2h. The impact of graphene on the performance of silicon–carbon composite-based anode materials for lithium-ion batteries (LIBs) was investigated. Transmission electron microscopy (TEM) and selected area electron diffraction (SAED) images of (Si/graphite/graphene)@C showed that the nano-Si and graphene particles were dispersed on the surface of graphite, and thermogravimetric analysis (TGA) curves indicated that the content of silicon in the (Si/graphite/graphene)@C was 18.91%. More bituminous cracking carbon formed on the surface of the (Si/graphite/graphene)@C due to the large specific surface area of graphene. (Si/Graphite/Graphene)@C delivered first discharge and charge capacities of 860.4 and 782.1 mAh/g, respectively, initial coulombic efficiency (ICE) of 90.9%, and capacity retention of 74.5% after 200 cycles. The addition of graphene effectively improved the cycling performance of the Si-based anode materials, which can be attributed to the reduction of electrochemical polarization due to the good structural stability and high conductivity of graphene. Full article

Cobalt(II) chloride (CoCl₂) being in the vicinity of polyimide chains entails modifications in terms of the molecular dynamics, which are mainly governed by the possible presence of amic acid residual groups, by the transition-metal-type characteristics of cobalt and by the CoCl₂ content. Polyimide was synthesized using poly(amic acid) according to the reaction of 2,2′-bis(3,4-dicarboxylphenyl)hexafluoropropane dianhydride (6FDA) with 3,3′-dimethyl-4,4′-diaminodiphenylmethane (MMDA) in N,N-dimethylacetamide. CoCl₂ was added before the thermal imidization of the poly(amic acid). An experimental approach was designed to establish the interaction between the polyimide and CoCl₂ and whether the interaction depends on the quantity of the salt. Evidence for the existence of residual amic acid groups was obtained using second derivative Fourier Transform Infrared Spectroscopy (FTIR) and with the help of 2D correlation spectroscopy (2D-COS). Moreover, FTIR, along with X-ray photoelectron spectroscopy (XPS), revealed the interaction between the polymer and CoCl₂, primarily in the form of Co(II)-N coordinated bonds. Nevertheless, the coordination of cobalt with suitable atoms from the amic acid groups is not precluded. The results of dynamic mechanical analysis (DMA) featured a specific relaxation assigned to the presence of CoCl₂ in the polymeric film and demonstrated that its (non)reinforcing effect depends on its content in the polyimide. Full article

Investigations regarding the preparation and durability of cement-based materials applied in specific coastal acid rain environments are scarce, particularly those involving the addition of four auxiliary cementitious materials (ACMs) to cement for modification. To improve the durability of concrete structures in coastal acid rain areas, a systematic study was conducted regarding the preparation of high-strength and corrosion-resistant cement-based materials using ACM systems composed of fly ash (FA), granulated blast furnace slag (GBFS), silica fume (SF), and desulfurization gypsum (DG) instead of partial cement. Through an orthogonal experimental design, the effect of the water–binder ratio, cementitious ratio, and replacement cement ratio on the compressive strength, corrosion resistance coefficient, and chloride ion permeability coefficient of the materials were analyzed and the mix proportions of the materials were evaluated and optimized using the comprehensive scoring method. The results show that implementing a FA:GBFS:SF:DG ratio of 2:6:1:1 to replace 60% of cement allows the consumption of calcium hydroxide crystals generated through cement hydration, promotes the formation of ettringite, optimizes the pore structures of cementitious materials, and improves the compressive strength, acid corrosion resistance, and chloride ion permeability of the materials. This study provides a reference for selecting concrete materials for buildings in coastal acid rain environments. Full article

In the present investigation, the corrosion tendency of mild steel under acidic pH was studied by employing unused expired amiodarone (EAD) drug as a potential corrosion inhibitor by adopting the weight loss measurement method. The corrosion inhibition efficiency (IE) of the formed protective film (EAD) on the steel surface was analyzed using potentiodynamic polarization and AC-impedance spectroscopy studies. The surface morphology of the mild steel before and after corrosion (in 1.0 M HCl) was analyzed via scanning electron microscopy–energy dispersive X-ray spectroscopy (SEM–EDAX), atomic force microscopy (AFM), and thermodynamic studies. The weight loss measurement under different concentrations of EAD indicated that an excellent inhibition was displayed at a concentration of 0.001 M, and the IE was found to depend on both the concentration and molecular structure of EAD. A potentiodynamic polarization study revealed that EAD predominantly acted as a cathode inhibitor, and electrochemical impedance spectroscopy (EIS) confirmed the adsorption of EAD on the surface of mild steel, which obeyed Temkin’s adsorption isotherm model. The calculated thermodynamic parameters revealed that adsorption was spontaneous and exothermic. Full article

Metal binder jetting shows great potential for medical technology. This potential can be exploited by integrating binder jetting into existing process routes known from metal injection molding. The biggest challenge here is the flowability and packing behavior of the powders used, due to their low size distributions. This paper investigates different powder-drying strategies to improve flowability using a statistical experimental design. Because of its relevance for medical applications, spherical Ti-6Al-4V powder with a size distribution under 25 µm is dried under various parameters using vacuum and gas purging. The investigated parameters, time and temperature, are selected in a central-composite-circumscribed test plan with eleven tests and three center points. The target parameters—water content, flowability and impurity levels (oxygen, nitrogen)—of the powder are analyzed. For validation, practical test trials are carried out on an industrial binder jetting system with unconditioned powder and conditioning with optimized parameters, comparing the manufactured parts and the powder bed. An optimized drying cycle with a duration of 6 h at 200 °C was determined for the investigated powder. Significant improvements in the dimensional accuracy (from ±1.5 to 0.3%) of the components and the visual impression of the powder bed are demonstrated. Full article

Externally bonded wet-layup carbon fiber-reinforced polymer (CFRP) strengthening systems are extensively used in concrete structures but have not found widespread use in deficient steel structures. To address the challenges of the adhesive bonding of wet-layup CFRP to steel substrates, this study investigated the effect of core–shell rubber (CSR) nanoparticles on the curing kinetics, glass transition temperature ($T_g$) and mechanical properties of ambient-cured epoxy/CSR blends. The effects of silane coupling agent and CSR on the adhesive bond properties of CFRP/steel joints were also investigated. The results indicate that CSR nanoparticles have a mild catalytic effect on the curing kinetics of epoxy under ambient conditions. The effect of CSR on the $T_g$ of epoxy was negligible. Epoxy adhesives modified with 5 to 20%wt. of CSR nanoparticles were characterized with improved ductility over brittle neat epoxy; however, the addition of CSR nanoparticles reduced tensile strength and modulus of the adhesives. An up to 250% increase in the single-lap shear strength of CFRP/steel joints was accomplished in CSR-modified joints over neat epoxy adhesive joints. Full article

Plastic waste disposal is a major environmental problem worldwide. One recycling method for polymeric materials is their conversion into carbon materials. Therefore, a process of obtaining activated carbons through the carbonization of waste CDs (as the selected carbon precursor) in an oxygen-free atmosphere, and then the physical activation of the obtained material with CO₂, was developed. Dyes such as methylene blue (MB) and malachite green (MG) are commonly applied in industry, which contaminate the water environment to a large extent and have a harmful effect on living organisms; therefore, adsorption studies were carried out for these cationic dyes. The effects of the activation time on the physicochemical properties of the activated materials and the adsorption capacity of the dyes were investigated. The obtained microporous adsorbents were characterized by studying the porous structure based on low-temperature nitrogen adsorption/desorption, scanning electron microscopy (SEM-EDS), elemental analysis (CHNS), Raman spectroscopy, X-ray powder diffraction (XRD), infrared spectroscopy (ATR FT-IR), thermal analysis (TG, DTG, DTA), Boehm’s titration method, and pH_pzc (the point of zero charge) determination. Moreover, adsorption studies (equilibrium and kinetics) were carried out. The maximum adsorption capacities (q_{m exp}) of MB and MG (349 mg g⁻¹ and 274 mg g⁻¹, respectively) were identified for the obtained material after 8 h of activation. The results show that the use of waste CDs as a carbon precursor facilitates the production of low-cost and effective adsorbents. Full article

Ultra-high-performance concrete (UHPC), a new cement-based material that offers high mechanical strength and good durability, has been widely applied in construction and rehabilitation projects in recent years. An optimum bending system is achieved by positioning the UHPC layer at the bottom tensile zone of the composite beam and placing the normal-strength concrete (NC) layer at the upper compression zone, which is described as the UHPC-NC composite beam. The fatigue behavior of reinforced UHPC-NC composite beams was described in this study, with an emphasis on the effects of UHPC layer thickness and fatigue load level on the fatigue life of the beam, deformation of the interface between UHPC and NC layers, as well as the bending stiffness of the beam. A total of 9 reinforced UHPC-NC composite beams were tested under cyclic loading. The test variables include UHPC layer thicknesses (zero, 200, and 360 mm), reinforcement ratios (1.184% and 1.786%), and the upper load levels (0.39~0.65). The results showed that good bonding had been achieved without delamination between UHPC and NC layers prior to the final fatigue failure of the beam, and the bending stiffness of the composite beam experienced a three-stage reduction under cyclic loading. Furthermore, an equation was proposed to predict the stiffness reduction coefficient of UHPC-NC composite beams under cyclic loading. Full article

One of the main types of uses of cellular materials is for energy absorption and dissipation in applications, such as safety and packaging, to protect people and goods during impact situations. In such cases, the use of cellular materials is justified by their capacity to largely deform under limited loads. This is often achieved, alone or within energy absorbing structures, with the additional advantage of cheap components that are relatively simple to manufacture and assemble. As in most engineering applications, weight reduction is sought after and, as in the case of other materials, this objective can be attained by optimizing the use of the material. Optimization of a cellular material for energy absorption means obtaining an optimal mechanical characteristic that can be obtained by properly designing it in terms of the type of base material and cell properties. Cell properties are mainly related to density and their optimal selection can be made by means of energy criteria. The aim of the present paper is to discuss such optimality criteria based on what are termed efficiency diagrams to produce an effective design tool. Additionally, based on empiric observations on the behavior of several classes of polymeric foams, a simplified selection method is proposed to hasten the selection criteria. Full article

The eXtended finite element method (XFEM) is a powerful tool for structural mechanics, assisting engineers and designers in understanding how a material architecture responds to stresses and consequently assisting the creation of mechanically improved structures. The XFEM method has unraveled the extraordinary relationships between material topology and fracture behavior in biological and engineered materials, enhancing peculiar fracture toughening mechanisms, such as crack deflection and arrest. Despite its extensive use, a detailed revision of case studies involving XFEM with a focus on the applications rather than the method of numerical modeling is in great need. In this review, XFEM is introduced and briefly compared to other computational fracture models such as the contour integral method, virtual crack closing technique, cohesive zone model, and phase-field model, highlighting the pros and cons of the methods (e.g., numerical convergence, commercial software implementation, pre-set of crack parameters, and calculation speed). The use of XFEM in material design is demonstrated and discussed, focusing on presenting the current research on composites and biological and bioinspired materials, but also briefly introducing its application to other fields. This review concludes with a discussion of the XFEM drawbacks and provides an overview of the future perspectives of this method in applied material science research, such as the merging of XFEM and artificial intelligence techniques. Full article

Lightning strike events pose significant challenges to the structural integrity and performance of composite materials, particularly in aerospace, wind turbine blade, and infrastructure applications. Through a meticulous examination of the state-of-the-art methodologies of laboratory testing and damage predictive modeling, this review elucidates the role of simulated lightning strike tests in providing inputs required for damage modeling and experimental data for model validations. In addition, this review provides a holistic understanding of what is there, what are current issues, and what is still missing in both lightning strike testing and modeling to enable a robust and high-fidelity predictive capability, and challenges and future recommendations are also presented. The insights gleaned from this review are poised to catalyze advancements in the safety, reliability, and durability of composite materials under lightning strike conditions, as well as to facilitate the development of innovative lightning damage mitigation strategies. Full article

To investigate the effect of the sintering temperature on the microstructure characteristics of porous NiTi alloys, two types of porous NiTi alloys with equal atomic ratios were fabricated via elemental powder sintering at 950 °C and 1000 °C. Afterwards, optical microscopy (OM), scanning electron microscopy (SEM) and transmission electron microscopy (TEM) were collectively applied to investigate the pore characteristics and microstructure of the fabricated porous NiTi alloy. The results show that when the sintering temperature increases from 950 °C to 1000 °C, the average pore size increases from 36.00 μm to 181.65 μm, owing to the integration of these newly formed small pores into these pre-existing large-sized pores. The measured density increases from 2.556 g/cm³ to 3.030 g/cm³, while the porosity decreases from 60.4% to 51.8%. This is due to the occurrence of shrinkage after the sufficient diffusion of atoms. Furthermore, the characterization results confirm that a change in the sintering temperature would not change the phase types within a porous NiTi alloy; namely, the matrix consists primarily of B2 NiTi, with a significant amount of Ni₄Ti₃ precipitates and a small amount of Ni₃Ti precipitates and Ti₂Ni precipitates. However, as the sintering temperature increases, the number of Ni₄Ti₃ precipitates decreases significantly. The formation of a Ni₄Ti₃ phase in the present study is closely related to the enrichment of Ni content in the matrix owing to the diffusion rate difference between Ni atoms and Ti atoms and the absence of a transient liquid phase (TLP) during the sintering process owing to the relatively low sintering temperature (lower than the eutectic temperature). Moreover, the increasing sintering temperature speeds up the atom diffusion, which contributes to a reduction in the enrichment of Ni as well as the number of formed Ni₄Ti₃ precipitates. Full article

Wire-arc additive manufacturing (WAAM) is a promising industrial production technique. Without optimization, inherent temperature gradients can cause powerful residual stresses and microstructural defects. There is therefore a need for data-driven methods allowing real-time process optimization for WAAM. This study focuses on machine learning (ML)-based prediction of temperature history for WAAM-produced aluminum bars with different geometries and process parameters, including bar length, number of deposition layers, and heat source movement speed. Finite element (FE) simulations are used to provide training and prediction data. The ML models are based on a simple multilayer perceptron (MLP) and performed well during baseline training and testing, giving a testing mean absolute percentage error (MAPE) of less than 0.7% with an 80/20 train–test split, with low variation in model performance. When using the trained models to predict results from FE simulations with greater length or number of layers, the MAPE increased to an average of 3.22% or less, with greater variability. In the cases of greatest difference, some models still returned a MAPE of less than 1%. For different scanning speeds, the performance was worse, with some outlier models giving a MAPE of up to 14.91%. This study demonstrates the transferability of temperature history for WAAM with a simple MLP approach. Full article

Metal-coated lattice structures hold significant promise for customizing mechanical properties in diverse industrial applications, including the mechanical arms of unmanned aerial vehicles. However, their intricate geometries pose computational challenges, resulting in time-intensive and costly numerical evaluations. This study introduces a parameterization-based multiscale method to analyze body-centered cubic lattice structures with metal coatings. We establish the validity and precision of our proposed method with a comparative analysis of numerical results at the Representative Volume Element (RVE) scale and experimental findings, specifically addressing both elastic tensile and bending stiffness. Furthermore, we showcase the method’s accuracy in interpreting the bending stiffness of coated lattice structures using a homogenized material-based solid model, underscoring its effectiveness in predicting the elastic properties of such structures. In exploring the mechanical characterization of coated lattice structures, we unveil positive correlations between elastic tensile stiffness and both coating thickness and strut diameter. Additionally, the metal coating significantly enhances the structural elastic bending stiffness multiple times over. The diverse failure patterns observed in coated lattices under tensile and bending loads primarily stem from varied loading-induced stress states rather than external factors. This work not only mitigates computational challenges but also successfully bridges the gap between mesoscale RVE mechanical properties and those at the global structural scale. Full article

Super 304H has been a crucial material for ultra-supercritical boilers. However, the relationship between microstructure evolution, strengthening mechanism, and embrittling behavior during long-term aging was lacking investigation. This investigation aimed to reveal the strengthening and embrittling mechanism from precipitates in Super 304H. The results showed that the hardness increment came from the grain boundary’s M₂₃C₆ (GB’s M₂₃C₆) and intragranular nano Cu-rich particles. After being aged for 5000 h, the GB’s M₂₃C₆ and nano Cu-rich particles provided a hardness increment of approximately 10 HV and 30 HV, respectively. The impact toughness gradually decreased from 213 J/cm² to 161 J/cm² with the extending aging time. For the aged Super 304H, the GB’s M₂₃C₆ provided a higher cracking source. In addition, the nano Cu-rich particle restricted the twin-induced plastic deformation of austenitic grain and depressed the absorbed energy from austenitic grain deformation. Full article