Search Results (1,904)

The production of fiber-reinforced polymer composites using 3D printing technology offers significant potential and opportunities for industrial applications. However, current dimensional limitations in 3D printing necessitate the use of joining techniques to obtain larger components. Recently, innovative strategies such as friction stir spot welding (FSSW) have attracted considerable attention for joining polymer composites due to their ability to produce strong joints with relatively low heat input (solid-state welding). Nevertheless, it is important to understand how the fibers present in fiber-reinforced polymer composites influence material flow and welding performance during the FSSW process. In this study, glass fiber-reinforced polylactic acid (PLA-GF) composite samples produced using a 3D printer were joined by means of FSSW. Five different tool rotational speeds (900, 1200, 1500, 1800, and 2100 rpm) and three different plunge rates (10, 20, and 30 mm/min) were employed during the welding process. Mechanical tests were performed on the welded joints to investigate the relationship between the welding parameters and the resulting mechanical properties. In addition, microstructural analyses were conducted to examine the formation of welding defects. The results revealed that three distinct zones were formed in the material after the FSSW process: the stir zone, mixed zone, and shoulder zone. Defects were observed in the mixed zone of the samples exhibiting relatively lower mechanical properties. The highest tensile force was achieved at a plunge rate of 20 mm/min and a rotational speed of 900 rpm. The highest bending force, on the other hand, was obtained at a plunge rate of 30 mm/min and a tool rotational speed of 2100 rpm. Full article

Artificial composite stones have recently attracted attention as multifunctional materials for construction and defense-related applications. In this study, a novel composite stone was developed using waste limestone as the primary mineral filler, combined with an unsaturated polyester resin matrix and reinforced with glass powder and chopped glass fibers. The influence of binder content and reinforcement type on physico-mechanical and microstructural behavior was investigated. Experimental characterization included water absorption, compressive strength, abrasion resistance, acid resistance, and optical microscopy. The results demonstrated that fine fillers improved matrix densification and reduced porosity, while short glass fiber reinforcement enhanced load-bearing capacity. Abrasion resistance and durability were found to depend on binder content and particle packing characteristics. Overall, the developed composite material exhibits promising mechanical performance, low water absorption, and improved durability, suggesting its potential as a candidate material for applications requiring environmental resistance, including potential use in defense-related camouflage applications. Full article

This study investigates the mechanical properties and internal pore structure characteristics of raw phosphogypsum–basalt fiber (RPG-BF) cementitious materials with varying raw phosphogypsum (PG) replacement ratios. Specifically, six different PG addition levels (0%, 3%, 6%, 9%, 12%, and 15% by mass of cementitious materials) with a constant basalt fiber dosage of 0.1% (by volume of concrete) were adopted. The mechanical properties of RPG-BF cementitious materials were evaluated by testing the 7-day and 28-day compressive strengths, 28-day split tensile strength, and 28-day flexural strength. Meanwhile, the pore distribution characteristics of the RPG-BF cementitious materials were systematically analyzed using liquid nitrogen adsorption (LNA) tests and scanning electron microscopy (SEM) observations. The experimental results indicate the following: (a) With an increase in PG content, the mechanical properties of RPG-BF cementitious materials exhibit a significant downward trend: the 28-day compressive strength, split tensile strength, and flexural strength decrease by 49%, 44%, and 43%, respectively. (b) The internal pores of the RPG-BF cementitious materials possess excellent fractal characteristics, with fractal dimensions ranging from 2.52 to 2.62. As the PG content increases, the pore structure becomes more intricate and less homogeneous, which is a microstructural factor associated with the degradation of mechanical properties. (c) There exists a strong Pearson’s linear correlation (R > 0.82, with R² ranging from 0.67 to 0.94) between the pore fractal dimension of RPG-BF cementitious materials and their 7-day/28-day compressive strength, split tensile strength, and flexural strength. (d) SEM observations show that the quantity of micropores and microcracks in the RPG-BF cementitious materials increases with increasing PG content, further confirming deterioration of the material microstructure. Full article

To further improve the mechanical properties of shotcrete in coal mine roadways, end-hooked steel fibers and chopped basalt fibers were selected. Based on the optimal mix ratios identified in existing research, steel–basalt hybrid fiber shotcrete (SBFC) specimens were prepared. Dynamic impact tests under different impact loads and various hybrid fiber contents were conducted using an SHPB. The microstructure was characterized using SEM and XRD. The results show that the dynamic compressive stress–strain curve of steel–basalt hybrid fiber shotcrete can be classified as elastic deformation stage, plastic yield stage, and post-peak failure stage. The incorporation of hybrid fibers reduces the elastic deformation and plastic yield stage, and the post-peak failure stage under active confining pressure shows elastic aftereffect characteristics. The dynamic compressive strength, dynamic elastic modulus, and deformation modulus increase with the increase in impact pressure and fiber content. When there is no confining pressure, the maximum dynamic compressive strength, dynamic elastic modulus, and modulus of deformation of SBFC4 reached 53.1 ± 2.2 MPa, 4.51 ± 0.3 GPa, and 2.55 ± 0.1 GPa, respectively, representing increases of 37.20%, 264.01%, and 59.37% compared with the control group. The dynamic compressive strength increases with the average strain rate, demonstrating a favorable strain rate effect. The energy–time history curves can be roughly divided into initial, growth, and stable stages. Under the same impact load conditions, as the fiber content gradually increases, the incident energy, dissipated energy, and energy utilization rate of the specimens all show a gradual upward trend. SEM and XRD results show that steel fibers and basalt fibers maintain good bonding with the cement matrix, contribute to the formation of gel and crystalline products within the specimens, effectively delay the initiation and propagation of cracks, and thereby improve the mechanical properties of the concrete specimens. Full article

Controlling the microstructure of electroless nickel coatings is crucial for optimizing the interfacial properties of carbon fibers. However, a systematic understanding of how dispersants can effectively leverage the refining effect of nanoparticles in composite plating systems remains lacking. This paper proposes the use of a composite dispersant, comprising polyethylene glycol (PEG) and sodium methylene bis-naphthalene sulfonate (NNO) at a 1:1 mass ratio, for nano-Al₂O₃ to achieve microstructure refinement of nickel coatings on carbon fiber surfaces. The results demonstrate that the composite dispersant modifies the surface state and dispersion stability of Al₂O₃ particles through synergistic adsorption, thereby regulating the nucleation and growth behavior of the Ni-P alloy. At an optimal composite dispersant concentration of 3 g/L, the coating exhibits the most compact structure, with Ni-P particle size refined to approximately 181 nm. The coating consists of two phases: crystalline Ni₃P and amorphous Ni-P. The dual adsorption effect of the dispersant—inhibiting Al₂O₃ agglomeration while improving the surface wettability of carbon fibers—is key to enhancing the refinement efficiency. Conversely, excessive dispersant addition leads to deteriorated coating quality. This study provides experimental evidence for understanding the multiphase interfacial interaction mechanism involving organic additives, nanoparticles, and metal deposition, and offers a novel strategy for controlling the surface functionalization of carbon fibers. Full article

In order to investigate the effects of bentonite and glass fiber on the macroscopic mechanical properties and microscopic mechanisms of cement soil in dry environments, a series of laboratory tests were conducted in this study, including drying tests under controlled environments (30 °C, 50% humidity), unconfined compressive strength (UCS) tests, digital image processing technology, and scanning electron microscopy (SEM) analyses. The moisture evaporation law, surface crack development process, UCS variation, and microstructure evolution of cement soil with different mix proportions (bentonite content: 0–9%; glass fiber content: 0–0.5%) were systematically analyzed. The results show that bentonite can significantly enhance the water retention capacity of cement soil, reduce the water evaporation rate, and increase the unconfined compressive strength by filling internal pores to densify the microstructure. Glass fibers form a three-dimensional network structure in the matrix, exerting a bridging effect to inhibit crack initiation and propagation, and optimize the mechanical properties. The unconfined compressive strength increases significantly with an increase in bentonite content (3–9%), and the optimal fiber content for strength improvement is determined as 0.3%. The synergistic effect of bentonite and fibers optimizes the interfacial bonding force between fibers and the matrix, which remarkably improves the anti-cracking performance of cement soil. Specifically, when the bentonite content is 6–9% and the fiber content is 0.3–0.5%, the cement soil maintains complete integrity after drying, with no obvious cracks on the surface. SEM analysis reveals that the addition of bentonite and fibers inhibits the expansion and connection of internal voids, avoiding the cycle of “void enlargement–stress concentration–crack propagation”. This study provides a scientific basis for the engineering application of cement soil in a dry environment. Full article

Palm kernel oil is commonly incorporated into plant-based cheeses to mimic the textural and structural properties of animal fats owing to its high saturated fat content. Nevertheless, growing concerns regarding saturated fat consumption have stimulated research into alternative lipid sources for plant-based products. Therefore, this study aimed to evaluate the effects of substituting palm kernel oil with rice bran oil shortening (SRBO) on some selected physical, textural, functional, chemical, fatty acid and microstructural properties of plant-based mozzarella cheese analogs. Five formulations with SRBO levels of 0, 25, 50, 75, and 100% were prepared and their physicochemical properties were analyzed. Increasing SRBO significantly affected color due to natural pigments in rice bran oil. The pH value declined with higher SRBO, likely due to oxidation of unsaturated fatty acids. Texture profile analysis showed increases in hardness, springiness, cohesiveness, gumminess, and chewiness when SRBO was increased from 0% to 100%. Meltability slightly decreased at 25–75% but remained unchanged at 100% SRBO, while stretchability decreased significantly, attributed to β-type fat crystals disrupting protein networks. The work of shear decreased significantly (p ≤ 0.05), indicating improved spreadability attributed to the softer, less-crystalline nature of unsaturated fats compared to saturated fats. Proximate analysis revealed reduced fat content and a shift from saturated to unsaturated fats, notably oleic and linoleic acids, offering potential cardiovascular benefits. Confocal laser scanning microscopy showed denser fat crystal networks and smaller fat droplets at higher SRBO levels, enhancing oil retention and stability. Protein, fiber, moisture, and ash content remained stable across samples. These findings suggested that SRBO could be a functional and health-conscious alternative to palm kernel oil in plant-based mozzarella cheese, improving nutritional quality without compromising texture or functionality. Full article

The effect of microstructural evolution on mechanical behavior of carbon/carbon composites after heat treatment has been investigated. Two kinds of samples, heat-treated at 2300 °C and 2700 °C, were used in the current study. As the heat treatment temperature is 2700 °C, the pyrolytic carbon acquires a higher orientation via carbon atomic layer rearrangement, accompanied by microstructural evolution such as self-healing of concentric ring cracks, narrowing of the fiber/matrix interface and bridging between adjacent fibers. This microstructural evolution results in a significant decline in the mechanical properties of the composites: compressive strength, flexural strength, and shear strength decreased by approximately 60%, 68%, and 71%, respectively, while the corresponding fracture strains increased by 52%, 25%, and 19%, respectively, indicating an improvement in pseudoplasticity. Full article

This work presents a comparative study of micro- and nano-scale fillers in liquid composite molding processes, focusing on how particle size and morphology affect resin rheology, flow behavior, and filler filtration within fiber preforms. Glass microspheres and organo-modified montmorillonite were dispersed in epoxy resin and injected through glass-mat preforms at different fiber volume fractions (ranging from 0.27 to 0.47). Our study integrates rheological characterization, in situ flow-front tracking, unsaturated permeability analysis, thermogravimetric quantification of retained particles, and microstructural observations by SEM. Despite their smaller loading, nanoclay suspensions showed a markedly higher viscosity increase than microsphere systems, yet their permeability remained nearly unchanged. In contrast, microsphere-filled resins exhibited strong filtration at the flow inlet, density-driven settling near the lower tool face, and significant permeability loss. The results demonstrate that nano-fillers, although more viscous, maintain homogeneous distribution and flow continuity, whereas micro-fillers promote cake formation and local compaction. This controlled side-by-side comparison clarifies how filler size and shape govern filtration mechanisms in liquid composite molding (LCM), providing design guidelines for processing filled resin systems without compromising part quality. Full article

This study investigates the development of sustainable dry-mix shotcrete incorporating fly ash and silica fume as partial cement replacements in order to reduce the environmental impact of cement production. A total of 24 mixtures were systematically evaluated, with 10–30% supplementary cementitious material and 0.9–1.8 kg/m³ polypropylene fiber dosages. This research establishes a quantitative framework for optimizing mechanical performance, durability, and Global Warming Potential. Experimental results reveal that silica fume replacement increases 28-day compressive strength by up to 31.13%, while an optimal polypropylene fiber dosage of 0.9 kg/m³ provides a 15.87% strength enhancement through a matrix-bridging effect. Conversely, excessive fiber content (1.8 kg/m³) increases porosity, leading to a 14.94% reduction in strength. Durability analysis demonstrates that silica fume and fly ash significantly refine the microstructure, reducing sorptivity and limiting freeze–thaw strength loss to a range of 18.13% to 41.03%. Crucially, the 30% by volume of the cement replaced with silica fume mixture was identified as the optimum design, achieving the lowest Global Warming Potential per unit strength at 8.82 kg CO₂-eq/m³/MPa, compared to 18.75 for the high-fiber mixture. These findings provide new, specific evidence that these supplementary cementitious material blends can successfully produce dry-mix shotcrete with significantly lower carbon emissions. Full article

Steel processing requires energy-efficient heat-treatment routes without compromising material performance. Traditional annealing furnaces used for low-carbon (LC) steels are energy-intensive and major contributors to CO₂ emissions, creating a need for sustainable alternatives. This study evaluates continuous electric furnace (CEF) annealing as a low-emission route to tailor the microstructure, texture, and mechanical properties of cold-rolled LC steel. Samples were annealed at 750 °C and 850 °C for 60 s, followed by comprehensive microstructural and crystallographic characterization using XRD, SEM, EBSD (IPF, GOS, KAM, ODF), hardness, and tensile testing. Annealing increased recrystallization from ~4% in the as-rolled condition to ~98% at 850 °C, reduced the mean KAM from 1.9° to 0.1°, enhanced the high-angle grain boundary fraction to 0.91, and promoted γ-fiber strengthening while suppressing detrimental θ-fiber components. The 850 °C condition achieved optimal mechanical performance (UTS × TE = 11.1 GPa%). These results demonstrate that CEF annealing enables sustainable processing with better mechanical performance in LC steels. Full article

The growing need for lightweight, multifunctional, and high-performance structures in the automotive, aerospace, electronics, and medical industries has driven the development of advanced joining technologies for polymers and metal-polymer combinations. Among these, ultrasonic welding (USW) and friction stir spot welding (FSSW) have emerged as promising solid-state techniques capable of producing reliable joints with minimal thermal degradation and enhanced interfacial bonding. This review focuses on recent developments in USW and FSSW of thermoplastics, fiber-reinforced composites, and hybrid metal–polymer systems, with a particular emphasis on process mechanics, microstructural evolution, and joint performance. The mechanisms of heat generation, material flow behavior, and consolidation are discussed in relation to key process parameters, including applied pressure, rotational speed, vibration amplitude, plunge depth, and dwell time. Microstructural transformations such as polymer chain orientation, recrystallization, interfacial diffusion, and defect formation are analyzed to establish process–structure–property relationships. Mechanical performance metrics, including lap shear strength, fatigue resistance, impact behavior, and environmental durability, are critically compared across different materials and welding methods. Furthermore, recent advances in numerical and thermo-mechanical modeling, in situ process monitoring, and data-driven optimization are discussed to highlight pathways toward predictive and scalable manufacturing. Current industrial applications and existing limitations such as challenges in automation, thickness constraints, and hybrid material compatibility are also evaluated. Finally, key research gaps and future directions are identified to improve joint reliability, sustainability, and broader industrial adoption of advanced solid-state welding technologies. Full article

Red mud-based composites show great potential in industrial solid waste utilization in response to the growing demand for low-carbon building materials. However, red mud–coal metakaolin geopolymers (RCGs) exhibit high brittleness and poor crack resistance, which limit their application in practical engineering. In order to improve the strength and toughness of RCGs, this study proposes a hybrid reinforcement strategy combining basalt fiber (BF) and polypropylene fiber (PPF). Effects of fiber length and fiber content on the mechanical properties of RCG were systematically investigated by orthogonal experimental design and response surface methodology (RSM). The microstructural characteristics were also analyzed using SEM, EDS, and XRD. Results show that fiber incorporation effectively enhances the mechanical properties and toughness of RCG, and BF length is the key factor influencing the strength of RCG. The optimal fiber ratio (BF: 11 mm, 0.23%; PPF: 6 mm, 0.20%) increases 9.52% of 28-day compressive strengths and 18.93% of 28-day flexural strengths. Microstructural analysis shows fibers bridging, interfacial stress transfer, and pull-out, which inhibit crack propagation. However, excessive fiber content may reduce matrix continuity. This manuscript provides a theoretical basis for optimizing red mud-based geopolymer composites and promotes the resource utilization of industrial solid waste. Full article

In bridge widening projects under uninterrupted traffic conditions, vehicular vibration easily leads to damage in the interfacial transition zone (ITZ) and microstructural degradation of early-age concrete in wet joints. Taking a typical hollow slab-low T-beam widening structure as the object, this study introduces basalt micro fiber (BMF)-based ultra-high-performance concrete (UHPC) as the wet joint material and establishes a refined vehicle–bridge coupled dynamic model considering the time-varying stiffness of the joint material and road roughness excitation. The research indicates that although UHPC possesses excellent ultimate mechanical properties, its early-age setting process is extremely sensitive to vehicle-induced vibration. Numerical analysis reveals that while traditional temporary steel fixtures can effectively control the vertical relative displacement between the new and old girders within the critical value of 5.5 mm, the peak particle velocity (PPV) induced by heavy vehicles (buses and trucks) during the early pouring stage (<12 h) significantly exceeds the safety threshold of 3 mm/s, posing a severe threat to the directional distribution of steel fibers and interfacial bond strength. Therefore, this paper designs a single tuned mass damper (TMD) optimized based on Den Hartog’s fixed-point theory. Simulation results confirm that with the TMD configured, the vibration responses induced by buses across the entire speed range (≤120 km/h) are reduced below the safety limit; the vibration velocity induced by heavy trucks is also effectively controlled when combined with an 80 km/h speed limit. The collaborative strategy of “passive TMD vibration reduction + active traffic speed limit” proposed in this paper provides a theoretical basis for guaranteeing the early-age micro-forming quality of UHPC wet joints and overall traffic efficiency. Full article

In engineered cementitious composites (ECCs), the use of fine quartz sand is associated with high cost and is unfavorable for reducing ECC shrinkage. Moreover, the mining and processing of fine quartz sand impose negative environmental impacts. At the same time, the polyethylene (PE) or polyvinyl alcohol (PVA) fibers added to ensure ECC ductility are expensive, which limits the widespread application of ECCs. With the aim of waste utilization and cost reduction while improving efficiency, this study employs geopolymer aggregate (GPA) as an alternative to fine quartz sand and partially replaces PE fibers with steel fibers to develop an economical and environmentally friendly geopolymer aggregate ECC. Six groups of ECC specimens with different mix proportions were designed and tested under uniaxial compression, flexural loading, and uniaxial tension. Different aggregate types (fine quartz sand and geopolymer aggregate) and volume fraction ratios of PE fibers to steel fibers (0:2.0, 0.5:1.5, 1.0:1.0, 1.5:0.5, and 2.0:0) were adopted to investigate their effects on mechanical properties, microstructural characteristics, and material sustainability. The experimental results reveal the failure process and deformation characteristics of the ECCs at different loading stages. The results indicate that geopolymer aggregate, owing to its lower stiffness and fracture energy, can promote multiple cracking behavior in ECCs. Although the complete replacement of quartz sand with porous GPA initially causes a slight reduction in the compressive and flexural strengths of the matrix, the hybridization strategy—partially replacing PE fibers with steel fibers—effectively compensates for this strength loss while maintaining excellent ductility. By comparing sustainability indicators with those of conventional ECCs, the results demonstrate that hybrid fiber geopolymer aggregate ECCs can effectively reduce material costs and carbon dioxide emissions. These findings verify the sustainability of producing green ECCs using industrial solid waste as an aggregate and provide guidance for the application of environmentally friendly geopolymer aggregate ECCs. Full article