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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Advanced Materials Characterization".

Deadline for manuscript submissions: closed (20 February 2024) | Viewed by 17290

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Special Issue Editors

Dr. Janusz Kluczyński

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Guest Editor

Institute of Robots and Machine Design, Faculty of Mechanical Engineering, Military University of Technology, 2 Gen. S. Kaliskiego St., 00-908 Warsaw, Poland
Interests: additive manufacturing; selective laser melting; fused deposition modelling; mechanical properties of polymers and metals; fatigue properties

Dr. Marcin Małek

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Guest Editor

Research Laboratory of WIG, Faculty of Civil Engineering and Geodesy, Military University of Technology, 2 Gen. S. Kaliskiego St., 00-908 Warsaw, Poland
Interests: concrete; composite structures; mechanical properties; mortals; recycling; waste materials

Special Issue Information

Dear Colleagues,

Significant growth has been observed in industry branches strictly related to new materials, an observation valid for metals and polymers, but also for composite materials. Considering the increase in material costs, it has become exceedingly important to produce lightweight constructions through the use of certified materials with appropriate mechanical properties. Many composite materials, especially in building engineering, are characterized by using waste materials, allowing the obtainment of an eco-friendly factor and often also positively affecting the performance (as well as mechanical) properties of the whole construction. A similar phenomenon has been noticed in polymers and metals, with the ecologically friendly factor having increasingly more influence in such materials.

The main aim of our Special Issue is to gather all novel research results concerning different materials available for all important industries—building engineering, the heavy industry, automotive, aerospace, and medicine. Such a general title has been proposed to also include different manufacturing technologies using various materials—conventional (milling, casting, forming, and turning) and novel (hybrid and additive manufacturing).

Dr. Janusz Kluczyński
Dr. Marcin Małek
Guest Editors

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Keywords

mechanical properties
structural analysis
strength analysis
dynamic analysis
composites structures
metallic materials
polymers
fracture analysis
additive manufacturing

Published Papers (11 papers)

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Research

16 pages, 4098 KiB

Open AccessArticle

Annual Plants and Thermoplastics in the Production of Polymer and Lignocellulose Boards

by Aleksandra Banaszak, Magdalena Woźniak, Dorota Dziurka and Radosław Mirski

Materials 2023, 16(12), 4400; https://doi.org/10.3390/ma16124400 - 15 Jun 2023

Cited by 1 | Viewed by 749

Abstract

This study investigated the mechanical, physical, and thermal properties of three-layer particleboards produced from annual plant straws and three polymers: polypropylene (PP), high-density polyethylene (HDPE), and polylactic acid (PLA). The rape straw (Brassica napus L. var. Napus) was used as an internal layer, while rye (Secale L.) or triticale (Triticosecale Witt.) was applied as an external layer in the obtained particleboards. The boards were tested for their density, thickness swelling, static bending strength, modulus of elasticity, and thermal degradation characteristics. Moreover, the changes in the structure of composites were determined by infrared spectroscopy. Among the straw-based boards with the addition of tested polymers, satisfactory properties were obtained mainly using HDPE. In turn, the straw-based composites with PP were characterized by moderate properties, while PLA-containing boards did not show clearly favorable properties either in terms of the mechanical or physical features. The properties of straw–polymer boards produced based on triticale straw were slightly better than those of the rye-based boards, probably due to the geometry of the strands, which was more favorable for triticale straw. The obtained results indicated that annual plant fibers, mainly triticale, can be used as wood substitutes for the production of biocomposites. Moreover, the addition of polymers allows for the use of the obtained boards in conditions of increased humidity. Full article

(This article belongs to the Special Issue Mechanical Properties of Polymeric, Metallic, and Composite Materials)

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14 pages, 35770 KiB

Open AccessArticle

Static and Dynamic Mechanical Behaviour of Hybrid-PBF-LB/M-Built and Hot Isostatic Pressed Lattice Structures

by David Sommer, Cemal Esen and Ralf Hellmann

Materials 2023, 16(9), 3556; https://doi.org/10.3390/ma16093556 - 06 May 2023

Cited by 2 | Viewed by 1335

Abstract

We report on a comprehensive study of the mechanical properties of maraging steel body-centred cubic lattice structures fabricated by a hybrid additive manufacturing technology that combines laser powder bed fusion with in situ high-speed milling. As the mechanical properties of additive manufactured components are inferior to, e.g., cast components, surface modifications can improve the mechanical behaviour. Different hybrid additive manufacturing technologies have been designed using additive and subtractive processes, improving process quality. Following this, mechanical testing is performed with respect to static tensile properties and dynamic stress, hardness, and porosity, comparing specimens manufactured by laser powder bed fusion only to those manufactured by the hybrid approach. In addition, the influence of different heat-treatment techniques on the mechanical behaviour of the lattice structures is investigated, namely solution and aging treatment as well as hot isostatic pressing. Thus, the influence of the superior surface quality due to the hybrid approach is evaluated, leading to, e.g., an offset of about 14–16% for the static testing of HIP lattice structures. Furthermore, the dynamic load behaviour can be improved with a finished surface, heading to a shift of the different zones of fatigue behaviour in the testing of hybrid-built specimens. Full article

(This article belongs to the Special Issue Mechanical Properties of Polymeric, Metallic, and Composite Materials)

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12 pages, 6431 KiB

Open AccessArticle

Performance Properties of Cement–Glass Composite Bricks (CGCB) with Additively Manufactured (AM) Polymeric Scaffolding

by Marcin Małek, Janusz Kluczyński, Waldemar Łasica, Mateusz Jackowski, Ireneusz Szachogłuchowicz, Jakub Łuszczek, Janusz Torzewski and Krzysztof Grzelak

Materials 2023, 16(5), 1909; https://doi.org/10.3390/ma16051909 - 25 Feb 2023

Cited by 4 | Viewed by 1477

Abstract

This study provides an alternative to traditional masonry materials: a cement–glass composite brick (CGCB), with a printed polyethylene terephthalate glycol (PET-G) internal scaffolding (gyroidal structure). This newly designed building material consists of 86% waste (78% glass waste, and 8% recycled PET-G). It can respond to the construction market’s needs and provide a cheaper alternative to traditional materials. Performed tests showed an improvement in thermal properties after the use of an internal grate in the brick matrix, i.e., an increase in thermal conductivity (5%), and a decrease in thermal diffusivity (8%) and specific heat (10%). The obtained anisotropy of the CGCB’s mechanical properties was much lower than the non-scaffolded parts, indicating a very positive effect of using this type of scaffolding in CGCB bricks. Full article

(This article belongs to the Special Issue Mechanical Properties of Polymeric, Metallic, and Composite Materials)

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16 pages, 10412 KiB

Open AccessArticle

Process Parameter Investigation and Torsional Strength Analysis of the Additively Manufactured 3D Structures Made of 20MnCr5 Steel

by Bartłomiej Sarzyński, Janusz Kluczyński, Jakub Łuszczek, Krzysztof Grzelak, Ireneusz Szachogłuchowicz, Janusz Torzewski and Lucjan Śnieżek

Materials 2023, 16(5), 1877; https://doi.org/10.3390/ma16051877 - 24 Feb 2023

Cited by 1 | Viewed by 1113

Abstract

An ongoing growth of the available materials dedicated to additive manufacturing (AM) significantly extends the possibilities of their usage in many applications. A very good example is 20MnCr5 steel which is very popular in conventional manufacturing technologies and shows good processability in AM processes. This research takes into account the process parameter selection and torsional strength analysis of AM cellular structures. The conducted research revealed a significant tendency for between-layer cracking which is strictly dependent on the layered structure of the material. Additionally, the highest torsional strength was registered for specimens with a honeycomb structure. To determine the best-obtained properties, in the case of the samples with cellular structures, a torque-to-mass coefficient was introduced. It indicated the best properties of honeycomb structures, which have about 10% smaller torque-to-mass coefficient values than monolithic structures (PM samples). Full article

(This article belongs to the Special Issue Mechanical Properties of Polymeric, Metallic, and Composite Materials)

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19 pages, 8496 KiB

Open AccessArticle

Processability of 21NiCrMo2 Steel Using the Laser Powder Bed Fusion: Selection of Process Parameters and Resulting Mechanical Properties

by Jakub Łuszczek, Lucjan Śnieżek, Krzysztof Grzelak, Janusz Kluczyński, Janusz Torzewski, Ireneusz Szachogłuchowicz, Marcin Wachowski and Marcin Karpiński

Materials 2022, 15(24), 8972; https://doi.org/10.3390/ma15248972 - 15 Dec 2022

Cited by 2 | Viewed by 1270

Abstract

With the development and popularization of additive manufacturing, attempts have been made to implement this technology into the production processes of machine parts, including gears. In the case of the additive manufacturing of gears, the availability of dedicated materials for this type of application is low. This paper summarizes the results of research on the implementation of 21NiCrMo2 low-alloy steel, which is conventionally used to produce gears as a feedstock in the PBF-LB/M process. The work presents research on the selection of process parameters based on porosity measurements, static tensile tests, and hardness measurements. In addition, the article includes a mathematical model based on the quadratic regression model, which allows the estimation of the percentage of voids in the material depending on the assumed values of independent variables (laser power, scanning velocity, and hatch distance). The paper includes a range of process parameters that enable the production of elements made of 21NiCrMo2 steel with a density of over 99.7%. Additionally, comparative tests were carried out on PBF-LB/M-manufactured steel (in the state after printing and the state after heat treatment) and conventionally manufactured steel in terms of its mechanical and microstructural properties. The results showed that the steel exhibited similar mechanical properties to other carburizing steels (20MnCr5 and 16MnCr5) that have been used to date in PBF-LB/M processes and it can be used as an alternative to these materials. Full article

(This article belongs to the Special Issue Mechanical Properties of Polymeric, Metallic, and Composite Materials)

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16 pages, 7356 KiB

Open AccessArticle

Influence of Fabrication Method and Surface Modification of Alumina Ceramic on the Microstructure and Mechanical Properties of Ceramic–Elastomer Interpenetrating Phase Composites (IPCs)

by Paulina Kozera, Anna Boczkowska, Krzysztof Perkowski, Marcin Małek and Janusz Kluczyński

Materials 2022, 15(21), 7824; https://doi.org/10.3390/ma15217824 - 06 Nov 2022

Cited by 3 | Viewed by 1912

Abstract

The paper presents experimental results of the work conducted to improve the adhesion between alumina ceramics and urea-urethane elastomer in the interpenetrating phase composites (IPCs), in which these two phases are interpenetrating three-dimensionally and topologically throughout the microstructure. Measurements of the contact angle, surface roughness, and shear tests were used to evaluate the effectivity and select the quantity of a silane coupling agent and the ceramic fabrication method. The tests were conducted using samples of dense alumina ceramic obtained by three- or four-step methods. In the four-step process, hot isostatic pressing (HIP) was applied additionally. As a result of the coupling agent coat and HIP application, the ceramic substrate wettability by the elastomer was improved. The water contact angle was reduced from 80 to 60%. In the next step, porous ceramic preforms were fabricated using HIP sintering and a solution of silane coupling agent treated their surface. The composites were produced using vacuum-pressure infiltration of porous alumina ceramics by urea-urethane elastomer in liquid form. The influence of the coupling agent application on the microstructure and mechanical properties of the composites was estimated. The microstructure of the composites was identified using SEM microscopy and X-ray tomography. As a result of using the coupling agent, residual porosity decreased from 7 to 2%, and compressive strength, as well as stress at a plateau, increased by more than 20%, from 25 to 33 MPa and from 15 to 24 MPa, respectively, for the composites fabricated by infiltration ceramic preforms with 40% of porosity. Full article

(This article belongs to the Special Issue Mechanical Properties of Polymeric, Metallic, and Composite Materials)

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23 pages, 6649 KiB

Open AccessArticle

Gaussian Process for Machine Learning-Based Fatigue Life Prediction Model under Multiaxial Stress–Strain Conditions

by Aleksander Karolczuk, Dariusz Skibicki and Łukasz Pejkowski

Materials 2022, 15(21), 7797; https://doi.org/10.3390/ma15217797 - 04 Nov 2022

Cited by 8 | Viewed by 2124

Abstract

In this paper, a new method for fatigue life prediction under multiaxial stress-strain conditions is developed. The method applies machine learning with the Gaussian process for regression to build a fatigue model. The fatigue failure mechanisms are reflected in the model by the application of the physics-based stress and strain invariants as input quantities. The application of the machine learning algorithm solved the problem of assigning an adequate parametric fatigue model to given material and loading conditions. The model was verified using the experimental data on the CuZn37 brass subjected to various cyclic loadings, including non-proportional multiaxial strain paths. The performance of the machine learning-based fatigue life prediction model is higher than the performance of the well-known parametric models. Full article

(This article belongs to the Special Issue Mechanical Properties of Polymeric, Metallic, and Composite Materials)

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14 pages, 3575 KiB

Open AccessArticle

Flake Graphene as an Innovative Additive to Grease with Improved Tribological Properties

by Małgorzata Djas, Anna Matuszewska, Beata Borowa, Krystian Kowiorski, Piotr Wieczorek, Marcin Małek and Adrian Chlanda

Materials 2022, 15(21), 7775; https://doi.org/10.3390/ma15217775 - 04 Nov 2022

Cited by 3 | Viewed by 1571

Abstract

The paper presents the results of research on the use of flake graphene as an additive to plastic grease in order to improve its tribological properties. The influence of concentration (0.25–5.00 wt.%) and the form of graphene (graphene oxide, reduced graphene oxide) on selected properties of the base grease were investigated. It has been found that the addition of graphene flakes improves the anti-wear properties of the lubricant. The greatest improvement in the properties of the lubricant was achieved by using graphene at a concentration of 4.00 wt.%; the reduction in the average diameter of the wear scar was almost 70% for GO and RGO, compared to the base lubricant without the addition of graphene. Full article

(This article belongs to the Special Issue Mechanical Properties of Polymeric, Metallic, and Composite Materials)

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19 pages, 4011 KiB

Open AccessArticle

The Influence of the Type of Fibers on the Reduction of the Threshold Effect in the Transition Zone of a Railway Track

by Włodzimierz Idczak, Tomasz Lewandrowski, Dominik Pokropski, Grzegorz Rogojsz and Tomasz Rudnicki

Materials 2022, 15(16), 5730; https://doi.org/10.3390/ma15165730 - 19 Aug 2022

Viewed by 1145

Abstract

The presented article concentrates on the influence of various concrete additives in the form of fibers on the mechanical parameters of concrete so as to obtain the effect of gradual changes in these parameters, which is very important in the transition zone of the railway track. Steel, polymer and glass fibers, as well as concrete without additives, were accepted for the study. The effect of additives on the consistency of the mixture, compressive strength, frost resistance and elastic modulus was studied. The research concerned concrete samples and models of elements of the ballastless railway surface, i.e., track slab and concrete block supports. The track slab model was made of concrete without additives, while the models of supports were made both without and with additives. The studies were carried out in laboratory conditions. As a result, the tested concrete samples with various additives were ranked so that they could be used as a material for elements of the railway surface in the transition zones of engineering facilities on railway roads, which is important from the point of view of reducing the threshold effect occurring in these zones. Detailed laboratory tests were presented, the results of these studies were discussed, and final conclusions were drawn regarding the technology of materials and the methodology of constructing the transition zones of the railway surface in order to avoid or at least reduce the threshold effect existing in such zones. Full article

(This article belongs to the Special Issue Mechanical Properties of Polymeric, Metallic, and Composite Materials)

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13 pages, 4557 KiB

Open AccessArticle

Bending Strength of Polyamide-Based Composites Obtained during the Fused Filament Fabrication (FFF) Process

by Michał Mazurkiewicz, Janusz Kluczyński, Katarzyna Jasik, Bartłomiej Sarzyński, Ireneusz Szachogłuchowicz, Jakub Łuszczek, Janusz Torzewski, Lucjan Śnieżek, Krzysztof Grzelak and Marcin Małek

Materials 2022, 15(14), 5079; https://doi.org/10.3390/ma15145079 - 21 Jul 2022

Cited by 2 | Viewed by 1519

Abstract

The research shows the comparison between two types of polyamide-based (PA) composites and pure, base material. The conducted analysis describes how the additions of carbon fibers and glass microbeads affect the material’s properties and its behavior during the bending tests. All samples have been tested in the three main directions available during the FFF process. To extend the scope of the research, additional digital-image-correlation tests and fracture analyses were made. The obtained results indicated a positive influence of the addition of carbon fibers into the material’s volume (from 81.39 MPa in the case of pure PA to 243.62 MPa in the case of the PA reinforced by carbon fibers). Full article

(This article belongs to the Special Issue Mechanical Properties of Polymeric, Metallic, and Composite Materials)

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19 pages, 5355 KiB

Open AccessArticle

A Comparative Study on Laser Powder Bed Fusion of Differently Atomized 316L Stainless Steel

by Krzysztof Grzelak, Marcin Bielecki, Janusz Kluczyński, Ireneusz Szachogłuchowicz, Lucjan Śnieżek, Janusz Torzewski, Jakub Łuszczek, Łukasz Słoboda, Marcin Wachowski, Zenon Komorek, Marcin Małek and Justyna Zygmuntowicz

Materials 2022, 15(14), 4938; https://doi.org/10.3390/ma15144938 - 15 Jul 2022

Cited by 6 | Viewed by 1988

Abstract

The significant growth of Additive Manufacturing (AM), visible over the last ten years, has driven an increase in demand for small gradation metallic powders of a size lower than 100 µm. Until now, most affordable powders for AM have been produced using gas atomization. Recently, a new, alternative method of powder production based on ultrasonic atomization with melting by electric arc has appeared. This paper summarizes the preliminary research results of AM samples made of two AISI 316L steel powder batches, one of which was obtained during Ultrasonic Atomization (UA) and the other during Plasma Arc Gas Atomization (PAGA). The comparison starts from powder particle statistical distribution, chemical composition analysis, density, and flowability measurements. After powder analysis, test samples were produced using AM to observe the differences in microstructure, porosity, and hardness. Finally, the test campaign covered an analysis of mechanical properties, including tensile testing with Digital Image Correlation (DIC) and Charpy’s impact tests. A comparative study of parts made of ultrasonic and gas atomization powders confirms the likelihood that both methods can deliver material of similar properties. Full article

(This article belongs to the Special Issue Mechanical Properties of Polymeric, Metallic, and Composite Materials)

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