Materials

Adhesive fracture in layered structures is governed by subsurface crack evolution that cannot be accessed using surface-based diagnostics. Methods such as digital image correlation and optical spectroscopy measure surface deformation but implicitly assume a straight and uniform crack front, an assumption that becomes invalid for interfacial fracture with wide crack openings and asymmetric propagation. In this work, terahertz time-domain spectroscopy (THz-TDS) is combined with double-cantilever beam testing to directly map subsurface crack-front geometry in opaque adhesive joints. A strontium titanate-doped epoxy is used to enhance dielectric contrast. Multilayer refractive index extraction, pulse deconvolution, and diffusion-based image enhancement are employed to separate overlapping terahertz echoes and reconstruct two-dimensional delay maps of interfacial separation. The measured crack geometry is coupled with load–displacement data and augmented beam theory to compute spatially averaged stresses and energy release rates. The measurements resolve crack openings down to approximately 100 μm and reveal pronounced width-wise non-uniform crack advance and crack-front curvature during stable growth. These observations demonstrate that surface-based crack-length measurements can either underpredict or overpredict fracture toughness depending on the measurement location. Fracture toughness values derived from width-averaged subsurface crack fronts agree with J-integral estimates obtained from surface digital image correlation. Signal-to-noise limitations near the crack tip define the primary resolution limit. The results establish THz-TDS as a quantitative tool for subsurface fracture mechanics and provide a framework for physically representative toughness measurements in layered and bonded structures.

This study evaluated the effect of clockwise reciprocation motion used in the original Optimum Torque Reverse kinematics, compared with clockwise continuous rotation, on the cyclic fatigue strength of nickel–titanium rotary instruments (NiTi) with different metallurgical characteristics. A total of 120 instruments, ProFile and EndoSequence in sizes 25/.04, 30/.04, and 35/.04, were tested under continuous rotation or reciprocation motions (n = 10 per subgroup). Instruments were examined by optical and scanning electron microscopy to exclude manufacturing defects. Phase transformation temperatures were determined by differential scanning calorimetry, and cyclic fatigue testing was conducted using a custom device simulating a curved canal with a 6 mm radius and an 86° curvature. The time to fracture was recorded, and the number of cycles to fracture was calculated. Statistical comparisons were performed using the Mann–Whitney U test with a significance level of p < 0.05. Differential scanning calorimetry showed that ProFile instruments were fully austenitic at the test temperature, while EndoSequence instruments exhibited a mixed R-phase and austenitic structure. Clockwise reciprocation motion significantly increased cyclic fatigue resistance in all groups compared with clockwise continuous rotation. Time to fracture increased by 241.3% to 337.5%, and EndoSequence instruments consistently demonstrated higher fatigue resistance. The greatest relative improvement was observed in ProFile 35/.04, with a 422.4% increase in the number of cycles to fracture. Overall, the reciprocation motion markedly enhanced cyclic fatigue strength irrespective of metallurgical phase composition, indicating a practical mechanical benefit that may reduce the risk of instrument separation during endodontic procedures.

Interfacial adhesion between selective laser-melted (SLM) AlSi10Mg and polyimide (PI) insulating coatings is often limited by mismatched physicochemical properties. To improve adhesion, Al-rich and Si-rich microstructured surfaces were fabricated on the XY plane (perpendicular to the build direction) and the Z plane (parallel to the build direction) by acidic and alkaline etching, exploiting the characteristic microstructure of SLM AlSi10Mg. Surface topography, chemical composition, and wettability were characterized, and interfacial mechanical performance was evaluated by shear and pull-off tests. The microstructures increased surface roughness and improved wettability. The shear strength rose from 2.6 ± 1.5 MPa for the polished surface to 43.2 ± 8.6 MPa. The polished surface showed a pull-off strength of 2.2 ± 0.25 MPa. In pull-off tests, failure mainly occurred within the dolly/adhesive/PI system, indicating that the interfacial tensile strength exceeded the strength of the adhesive system; the maximum measured pull-off strength was 29.0 ± 1.3 MPa. Fractography predominantly showed cohesive failure in PI on Al-rich microstructures. Si-rich microstructures exhibited mixed failure, including fracture of the Si skeleton and tearing of PI, together with interfacial microcracks.