Search Results (245)

The deformation behavior of polymers is influenced not only by service conditions such as temperature and the strain rate but also significantly by the formation process. However, existing simulation frameworks typically treat injection molding and the in-service mechanical response separately, making it difficult to capture the impact of the thermal history on large deformation behavior. In this study, the deformation behavior of injection-molded polycarbonate (PC) was investigated by accounting for its thermal history during formation, achieved through combined experimental characterization and constitutive modeling. PC specimens were prepared via injection molding followed by annealing at different molding/annealing temperatures and durations. Uniaxial tensile tests were conducted using a Zwick universal testing machine at strain rates of 10⁻³–10⁻¹ s⁻¹ and temperatures ranging from 293 K to 353 K to obtain stress–strain curves. The effects of the strain rate, testing temperature, and annealing conditions were thoroughly examined. Building upon a previously proposed phenomenological model, a new constitutive framework incorporating thermal history effects during formation was developed to characterize the large deformation behavior of PC. This model was implemented in ABAQUS/Explicit using a user-defined material subroutine. Predicted stress–strain curves exhibit excellent agreement with the experimental data, accurately reproducing elastic behavior, yield phenomena, and strain-softening and strain-hardening stages. Full article

A Cu-11.85Al-3.2Mn-0.1Ti shape memory alloy (SMA) with excellent superelasticity and shape memory effect was successfully fabricated via selective laser melting (SLM). Increasing the energy density enhanced grain refinement, achieving a 90% refinement rate compared to cast alloy, with an average width of ~0.15 µm. Refined martensite lowered transformation temperatures and increased thermal hysteresis. Nanoscale Cu₂TiAl phases precipitated densely within the matrix, forming a dual strengthening network combining precipitation hardening and dislocation hardening. This mechanism yielded a room-temperature tensile strength of 829.07 MPa, with 6.38% fracture strain. At 200 °C, strength increased to 883.68 MPa, with 12.26% strain. The maximum tensile strength represents a nearly 30% improvement on existing laser-melted quaternary Cu-based SMAs. Full article

Traditional fiber-reinforced polymer (FRP) retrofit methods can restore the strength of reinforced concrete columns well, but stiffness is also partly restored. To increase the initial stiffness of retrofitted columns, this study investigated the seismic behavior of retrofitted resilient reinforced concrete (RRC) columns that were retrofitted by different methods, including high-strength mortar retrofit, carbon fiber-reinforced polymer (CFRP) retrofit, and CFRP and steel plate retrofit. In addition, the effect of the axial load was also considered. Quasi-static tests were conducted twice on five specimens, i.e., before and after repairing. The first test was used to create earthquake damage, and the second test was used to compare the seismic behavior of the retrofitted columns. The experimental results indicated that the CFRP retrofit method, whether with a steel plate or not, can restore the lateral resistance capacity well; furthermore, the drift-hardening behavior and self-centering performance were well maintained. The residual drift ratio of the CFRP-retrofitted column was less than 0.5%, even at a drift ratio of 3.5%, and less than 1% at the 6% drift ratio. However, the initial stiffness was only partly restored using the CFRP sheet. The introduction of steel plates was beneficial in restoring the initial stiffness, and the stiffness recovery rate remained above 90% when CFRP sheets and steel plates were used simultaneously. The strain distribution of the CFRP sheet showed that the steel plate did work at the initial loading stage, but the effect was limited. By using the steel plate, the CFRP hoop strain on the south side was reduced by 68% at the 6% drift ratio in the push direction and 38% in the pull direction. The axial strain of CFRP cannot be ignored due to the larger value than the hoop strain, which means that the biaxial stress condition should be considered when using an FRP sheet to retrofit RC columns. Full article

As the severe environmental impacts of plastic pollution demand determined action, the European Union (EU) has included recycling at the core of its policies. Consequently, evolving jurisdiction now aims to achieve a recycling rate of 65% for non-PET plastic bottles by 2040. However, the widespread use of post-consumer high-density polyethylene (rPE-HD) recyclates in household chemical containers is still limited by PP contamination, poor mechanical properties, and low environmental stress cracking resistance (ESCR). Although previous studies have explored the improvement of regranulate properties through additives, few have examined whether reducing the variety of extrusion blow-moulded PE-HD packaging could offer similar benefits. Therefore, two sorted fractions of rPE-HD hollow bodies were processed into regranulates under industrial conditions, including hot washing, extrusion, and deodorisation. Subsequently, both materials underwent comprehensive characterisation regarding their composition and performance. The opaque material, which was sourced from milk bottles in the UK, exhibited greater homogeneity with minor impurities, leading to improved ductility and melt strain hardening at moderate strain rates compared to the mixed material stream, which contained approximately 2.5% PP contamination. However, both rPE-HD recyclates exhibited similar short-term creep behaviour, relatively low strain hardening moduli, and were almost devoid of inorganic particles. Considering the sum of the investigated properties, melt blending with suitable virgin material is likely one of the most effective options to maximise regranulate utilisation in hollow bodies, followed by recycling-oriented packaging design (e.g., for efficient sorting), and the employment of advanced sorting technology. Full article

Traditional concrete has low tensile strength, is prone to cracking, and has poor durability, which limits its scope of application. Basalt Fiber Textile–Reinforced Concrete (BTRC), a new type of fiber-reinforced cement material, offers advantages such as light weight, increased strength, improved crack resistance, and high durability. It effectively addresses the limitations of traditional concrete. However, the tensile properties of BTRC have not been fully studied, especially with fine aggregate concrete as the matrix, and there are few reports on this topic. Therefore, this study conducted uniaxial tensile tests of Basalt Textile–Reinforced Fine Aggregate Concrete (BTRFAC) and systematically investigated the effects of two mesh sizes (5 mm × 5 mm and 10 mm × 10 mm) and two to four layers of fiber mesh on the tensile strength, strain hardening behavior, crack propagation, and ductile tensile mechanical properties of BTRFAC thin slabs. The tests revealed that an increase in the number of fiber mesh layers significantly reinforced the material’s tensile strength and ductility. The tensile strength of the 5 mm mesh specimen (four-layer mesh) reached 2.96 MPa, which is 193% higher than plain concrete, and the ultimate tensile strain increased by 413%. The tensile strength of the 10 mm mesh specimen (four-layer mesh) was 2.12 MPa, which is 109% higher than plain concrete, and the ultimate tensile strain increased by 298%. The strength utilization rate of the 5 mm and 10 mm mesh fibers was 41% and 54% respectively, mainly due to the weakening effect caused by interface slippage between the fiber mesh and the matrix. An excessively small mesh size may lead to premature debonding from the matrix, but its denser fiber distribution and larger bonding area exhibit better strain hardening characteristics. More than three layers of fiber mesh can significantly improve the uniformity of crack distribution and delay propagation of the main crack. A calculation formula for the tensile bearing capacity of BTRFAC thin slabs is proposed, and the error between the theoretical value and the experimental value was very small. This research provides a theoretical basis and reference data for the design and application of basalt fiber mesh–reinforced concrete thin slabs. Full article

To enhance the mechanical properties of 6063-T4 aluminum alloy tubes, surface mechanical grinding treatment was conducted under graphene-assisted lubrication. The effects of rotational speed and cooling conditions on the mechanical properties of aluminum alloy tubes under biaxial stress were systematically explored. It was found that increasing the rotational speed and cooling rate facilitates the formation of finer lamellar grains, higher-density nano-precipitates, and a reduced dislocation density on the tube surface. These microstructural characteristics significantly contribute to an increased yield strength and sustained strain hardening capacity during bulging deformation. This study proposes an innovative approach for improving the strength and toughness of light alloy components during integral forming, providing meaningful insights for future engineering applications. Full article

Calcareous sand, a critical construction material in reef engineering and building foundations, possesses unique internal microstructures and inherent mechanical properties. Given these characteristics, it is essential to thoroughly evaluate its strength under various loading conditions to ensure its reliability in building applications. This study examines the strength, deformation, and failure characteristics of calcareous sand through consolidated drained shear failure tests using a GDS stress path triaxial apparatus. The effects of shear rate, particle gradation, and compactness are systematically investigated to assess their impact on structural stability in building foundations and load-bearing applications. The results indicate that at low confining pressures, calcareous sand exhibits strain softening, whereas at higher confining pressures, strain hardening is observed. For samples with the same gradation, both peak deviatoric stress and failure strain increase linearly with confining pressure. The volume strain evolution during shear follows three stages: shear shrinkage, shear dilatancy, and stabilization. At low confining pressures, dilatancy is favored, while high confining pressures promote shrinkage. Additionally, under constant confining pressure, peak strength increases and failure strain decreases linearly with compactness. Increasing the loading rate from 0.01 to 0.1 mm/min results in a slight increase in the friction angle, with minimal impact on cohesion. Particle gradation plays a significant role in determining the shear strength of calcareous sand, as its effects vary depending on the combination of compactness and gradation. These findings provide valuable insights for the design and construction of stable building foundations, roadbeds, and other load-bearing structures in reef engineering and coastal developments, where calcareous sand is widely used. Full article

Fiber optic sensors are increasingly used to measure dynamic strain fields caused by the propagation of mechanical waves. Their low intrusiveness when embedded within a structure makes them suitable for a wide range of applications. In this paper, the feasibility of integrating fiber Bragg gratings (FBGs) into castable materials for ultrasonic applications is investigated. We employed castable polyurethane resins, which are widely used in industry due to their reproducible and durable mechanical properties. Our study began with an analysis of fiber integration by examining the 1D strain profiles of two polyurethane resins during their polymerization and also the impact of their hardening on the central wavelength value of several FBGs spectra. Subsequently, we assessed the sensitivity of FBGs to ultrasonic waves generated at 100 kHz after resin polymerization. Specifically, we explored how the fiber coating influences the rate of energy transfer from the host material to the fiber core. Our findings demonstrate that the central wavelength shift in the FBG reflectivity spectra, caused by shrinkage during resin polymerization, can reach up to 10 nm. This shift must be considered when selecting FBG wavelengths to prevent the reflectivity spectra from falling outside the permissible range of the interrogation system. We measured exploitable ultrasonic waves propagating in the resin samples. Preliminary observations suggest the presence of early arrivals, which could potentially correspond to crosstalk effects between the FBGs even though they are centered at different wavelengths. Furthermore, we show that in dynamic strain fields caused by ultrasonic wave propagation, both acrylate and polyimide coatings transmit similar amounts of energy to the fiber core. These preliminary results highlight the potential of using FBGs as ultrasonic wave sensors embedded in castable materials such as polyurethane resins. Full article

This study systematically investigates the synergistic effects of Cu addition (0–0.7 wt.%) and 2% pre-straining on the artificial aging, natural aging (NA), and bake-hardening response (BHR) of AA6111 alloy. The results reveal that Cu significantly enhances age-hardening capacity and accelerates artificial aging kinetics. The 0.7Cu alloy achieved a 14% higher peak hardness (106.9 HV) than the Cu-free alloy (93.8 HV) while reducing peak aging time by 50% (from 10 h to 5 h). Pre-straining further promoted hardening rates, shortening peak aging times to 2 h for the 0.7Cu alloy. Natural aging (NA) severely suppressed BHR in non-pre-strained alloys, reducing paint baking (PB) increments by 75–77.5% after 14 days. However, the introduction of pre-straining not only reduces the negative effects of NA but also improves the BHR. TEM analysis demonstrated that Cu addition accelerated the precipitation of fine GP zones and β″ phases while pre-straining introduced dislocations that acted as heterogeneous nucleation sites for Q′ phases, refining precipitates and suppressing NA cluster formation. The synergistic combination of 0.7Cu and pre-straining achieved a superior BHR yield strength increment of 68.1 MPa with retained ductility, highlighting its potential for automotive applications requiring balanced formability and post-forming strength. Full article

This study investigates the influence of thermal conductivity and hardness on computer numerical control (CNC) turning performance, focusing on key machining metrics—material removal rate (MRR), surface roughness (R_a), and surface waviness (W_a)—across five engineering materials: aluminum 6061, brass C26000, bronze C51000, carbon steel 1020, and stainless steel 304. Experimental results reveal a strong correlation between material properties and machining efficiency. Materials with high thermal conductivity (>100 W/m·K) exhibited up to 38% higher MRR and improved surface integrity compared to low-conductivity counterparts. Aluminum 6061 achieved the highest MRR (7.5 mm³/min at a 0.25 mm/rev feed rate), with the lowest R_a (~0.58 µm) and W_a (~0.4576 µm), confirming its excellent machinability and heat dissipation. Conversely, stainless steel 304, characterized by low thermal conductivity (16 W/m·K) and high hardness (210 HBW), recorded the lowest MRR (1.125 mm³/min), elevated R_a (>1.0 µm), and substantial waviness (W_a ~0.9442 µm), indicating severe tool wear and thermal deformation. A multivariable regression model incorporating cutting speed, feed rate, thermal conductivity, and hardness was developed to predict MRR, achieving high predictive accuracy (R² > 0.92) for high-conductivity materials. Deviations of ±0.5 mm³/min were observed in harder, low-conductivity materials due to nonlinear effects such as strain hardening and thermal expansion. Measurement uncertainty analysis, with an estimated expanded uncertainty of ±2.5% for MRR and ±0.02 µm for surface metrics, ensures the reliability of these findings. These results underscore the importance of material-specific machining parameter optimization to enhance productivity, surface quality, and tool longevity in high-precision industries, including aerospace, automotive, and biomedical manufacturing. Full article

Copper and its alloys are widely used in marine environments due to their excellent corrosion resistance and thermal conductivity. Cold spray technology can avoid the thermal damage to the underlying material and is suitable for the manufacturing and repair of parts. In this study, Cu coatings were prepared on 304 stainless steel substrates by high-pressure cold spray technology, and the effects of cold spray parameters on the microstructure, mechanical properties, and cavitation resistance were investigated. The coatings (Cu-N₂1, Cu-N₂2, and Cu-He) were prepared using distinct cold spray parameters: Cu-N₂1 and Cu-N₂2 employed nitrogen gas at 5 MPa/800 °C with different nozzle geometries, while Cu-He utilized helium gas at 3 MPa/600 °C. The results show that the porosity of the Cu coating prepared by cold spray technology is less than 0.1%. The coating treated with helium gas exhibits a higher bonding strength (81.3 MPa), whereas the coating treated with nitrogen demonstrates greater strain hardening (130–136 HV_0.1). XRD results show that no phase change or oxidation occurred for coatings under all cold spraying conditions. After the cavitation test, the mass loss of the Cu coating is significantly less than that of the as-cast copper. The Cu coating surface first develops holes, and with the increase in cavitation time, the hole area begins to increase. However, with prolonged cavitation exposure, the surface of as-cast copper has a large area of holes, and with the increase in cavitation time, the hole growth rate is faster. These observations indicate the cavitation resistance of the Cu coating prepared by cold spray is more than 10 times higher than that of the as-cast copper. This study highlights the potential application of cold spray technology in the preparation of high-performance anti-cavitation copper coatings. Full article

Focusing on the complex mechanical responses exhibited by semi-crystalline polymers under the coupled influences of strain hardening, strain-rate strengthening, and temperature softening, this paper proposes a phenomenological constitutive model employing a three-branch parallel structure. Using a hybrid global optimization algorithm, the optimal parameters for polypropylene were identified, attaining a coefficient of determination of 0.9834 and controlling the average absolute relative error within 6.4%. Moreover, the effectiveness of the proposed constitutive model was accurately validated through two material models from the LS-Dyna software 4.8.29 database, and the simulation results exhibited high consistency with the theoretical model. This study provides a high-confidence material model suitable for high-strain-rate simulation scenarios. Full article

This study developed a twinning-induced plasticity (TWIP) steel characterized by lightweight, high strength, and high toughness. Tensile tests were conducted at strain rates ranging from 10⁻⁴ to 6500 s⁻¹ using a universal testing machine and a Hopkinson bar to evaluate the material’s mechanical properties. A Johnson–Cook (J-C) constitutive model was developed based on the mechanical performance data for high-strain behavior. X-ray diffraction (XRD), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD) were employed to analyze the microstructural evolution and fracture mechanisms of tensile specimens. The results show that the TWIP steel exhibits positive strain rate sensitivity (PSRS) under both quasi-static and dynamic strain rates. At high strain rates, the yield strength increased from 1133.0 MPa to 1430.6 MPa, and the tensile strength rose from 1494.3 MPa to 1640.34 MPa. The J-C model fits well at strain rates of 1000 s⁻¹ and 3000 s⁻¹, but fitting errors increase at higher strain rates due to the competition between thermal softening and strain hardening. XRD results reveal no significant phase transformation occurred during deformation, with twinning being the dominant mechanism. As the strain rate increased, deformation twins appeared in the material’s microstructure, inducing plastic deformation during tensile testing. The twin volume fraction increases progressively with the strain rate. At high strain rates, secondary twins emerge and intersect with primary twins, refining the grains through mutual interaction. The TWIP effect enhances the material’s mechanical performance by improving its strength and ductility while maintaining its lightweight nature. Full article

This paper investigates the effect of strain rate on the mechanical deformation and microstructural development of dual-phase AlCrFe₂Ni₂ high-entropy alloy during quasi-static and dynamic compression processes. It is revealed that the as-cast AlCrFe₂Ni₂ alloy is composed of a mixture of FCC, disordered BCC, and ordered B2 crystal structure phases. The alloy shows excellent compressive properties under quasi-static and dynamic deformation. The yield strength exceeds 600 MPa while the compressive strength is more than 3000 MPa at the compression rates of 30% under quasi-static conditions. Under dynamic compression conditions, the ultimate compression stresses are 1522 MPa, 1816 MPa, and 1925 MPa with compression strains about 12.8%, 14.7%, and 18.2% at strain rates of 1300 s⁻¹, 1700 s⁻¹ and 2100 s⁻¹, respectively. The dynamic yield strength is approximately linear with strain rate within the specified range and exhibit great sensitivity. The strong localized deformation regions (i.e., adiabatic shear bands (ASBs)) appear in dynamically deformed samples by dynamic recrystallization due to the conflicting processes of strain rate hardening and heat softening. Full article

Additive manufacturing is increasingly used to produce metallic biomaterials, and post-processing is gaining increasing attention for improving the properties of as-built components. This study investigates the effect of work hardening followed by recrystallisation annealing on the tensile and nanoindentation behaviour of laser powder bed-fused (LPBF) 316L stainless steel, with the aim of optimising its mechanical properties. As-built and thermally stabilised (at 900 °C) specimens were prestrained in a uniaxially tensile manner at room temperature (0.12 plastic strain, ~75% of maximum work hardening) and subsequently annealed (at 900 °C or 1050 °C for 1 h). The microstructure and mechanical properties were then characterised by optical microscopy, SEM, EBSD, XRD, nanoindentation, and tensile testing. It was found that prestraining increased yield tensile strength (YTS) 1.2–1.7 times (to 690–699 MPa) and ultimate tensile strength (UTS) ~1.2 times (to 762–770 MPa), but decreased ductility 1.5 times. Annealing led to recovery and partial static recrystallisation, decreasing YTS (to 403–427 MPa), restoring ductility, and increasing the strain hardening rate; UTS and indentation hardness were less affected. Notably, the post-LPBF thermal stabilisation hindered recrystallisation and increased its onset temperature. Mechanical property changes under prestraining and annealing are discussed with respect to microstructure and crystalline features (microstrain, crystal size, dislocation density). All specimens exhibited ductile fractures with fine/ultra-fine dimples consistent with the as-built cellular structure. The combined treatment enhanced tensile strength whilst preserving sufficient ductility, achieving a strength–ductility product of 40.3 GPa·%. This offers a promising approach for tailoring LPBF 316L for engineering applications. Full article