Materials & Design最新文献

英文中文

Bioinspired dampers: Meniscus-inspired energy dissipation components

IF 7.6 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials & Design

Pub Date : 2025-02-07 DOI: 10.1016/j.matdes.2025.113639

Will Sterling , Sachin Gunda , Konstantin Kikinov , Jack Waghorne , Rasoul Mirghafari , Sundararajan Natarajan , Stephan Rudykh , Kalin Dragnevski , Daniel Bell , Olga Barrera

Nature provides examples of functionally graded porous structures that absorb energy effectively, such as the knee meniscus. The meniscus features a three-layered structure with varying porosity from the outer to inner layers. The tissue's porous spaces are fluid-saturated, facilitating energy dissipation and damping. Inspired by this architecture, two 3-layered porous geometries were designed, which consisted of thin outer layers and a thicker inner layer with higher porosity and permeability. They were created using image analysis (IA), computational fluid dynamics (CFD) simulations, and pore space segmentation (PSS). The PSS geometry shows a reduced peak pore diameter (

88 μ m

111 μ m

) and an increased density of lower throat lengths but a slightly larger throat radius compared to the CFD geometry. These differences significantly impact permeability, with PSS samples showing a peak of 1522 D versus 151 D in CFD samples. Energy dissipation capabilities were evaluated through cyclic compression experiments at varying rates and with different fluid viscosities. The dissipation energy density of the CFD geometry (

1.8 kPa

) was 2.5 times higher than that of the PSS geometry (

0.7 kPa

). Scanning Electron Microscopy (SEM) compression tests revealed deformation patterns, including crease formation, bulging, and permanent deformation.

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引用次数: 0

Data-driven inverse design of novel spinodoid bone scaffolds with highly matched mechanical properties in three orthogonal directions

IF 7.6 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials & Design

Pub Date : 2025-02-07 DOI: 10.1016/j.matdes.2025.113697

Hao Wang , Yongtao Lyu , Jian Jiang , Hanxing Zhu

Bone scaffolds are widely used in orthopedics for repairing bone defects and promoting bone regeneration. However, the issue of stress shielding caused by an excessive elastic modulus and mismatched anisotropy in bone scaffolds remains unresolved. Therefore, it is essential to design novel bone scaffolds with mechanical properties that closely match those of human bone. In this study, a novel data-driven inverse design framework was proposed to design spinodoid bone scaffolds by combining a back propagation neural network with a genetic algorithm. For spinodoid bone scaffold type Ⅰ, compared to the target human bone, the relative errors on the nine independent constants of elasticity matrix ranged from 0.090% to 6.444%. Similarly, for spinodoid bone scaffold type Ⅱ, the relative errors ranged from 0.000% to 7.084%. Both the elastic constants and the anisotropies of the novel bone scaffolds were highly matched to those of the target bone tissues in all the three orthogonal directions. Moreover, the results from data-driven inverse design were compared with those obtained from finite element analyses and validated by experimental tests. The proposed data-driven inverse design of spinodoid structures holds promise for further exploration in tissue engineering and other scientific fields.

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引用次数: 0

Energy-efficient microwave heating for rapid fabrication of porous carbon nanofibers

IF 7.6 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials & Design

Pub Date : 2025-02-06 DOI: 10.1016/j.matdes.2025.113702

Haoyue Zhao, Xinyu Li, Fangqin Su, Ning Qi, Jian Fang

High-temperature heat treatment is a crucial thermochemical process for pyrolysis/carbonization of carbon nanofibers (CNFs). However, the inefficient heat transfer process of traditional heating methods often results in inhomogeneous heating, low porosity, long preparation times, and high energy consumption. Here, we first use electrospinning and microwave heating techniques to rapidly fabricate porous CNFs with the help of microwave absorbers. To deeply understand the microwave heating mechanism and differences with traditional heating, we systematically investigate and analyze the effects of the type and concentration of the microwave absorbers, microwave heating parameters, and two heating mechanisms (microwave and traditional heating) on the fabrication of CNFs by experimental investigation and COMSOL simulations. Such microwave heating technique can enable an ultrafast heating rate (up to 250 °C min⁻¹ on average). Due to the rapid internal and volumetric heating, CNFs prepared using microwave heating exhibit a larger carbon content (92.86 %) and a larger BET specific surface area (687 m²/g) than their counterparts prepared using traditional heating methods (88.49 % and 460.7 m²/g). Moreover, the possible mechanisms of microwave heating have been explained. This work paves the way for the fabrication of porous CNFs and other advanced carbon nanomaterials using microwave heating techniques.

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引用次数: 0

Prediction of chloride concentration in concrete under multi-salt environment: Optimization of integrated algorithm based on MSCPO and interpretability analysis

IF 7.6 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials & Design

Pub Date : 2025-02-06 DOI: 10.1016/j.matdes.2025.113682

Daming Luo , Kanglei Du , Ditao Niu

The accurate prediction of chloride concentration is vital for assessing reinforced concrete structure durability. However, diverse erosion media in engineering environments with varying ion concentrations present challenges for traditional prediction methods. This study conducted accelerated experiments to create a concrete chloride ion dataset in a multi-salt environment, with adjustments for abnormal data. The Crested Porcupine Optimizer (CPO) algorithm was enhanced with adaptive techniques, and the refined strategy’s effectiveness was verified through test function analysis. The Improved Mixture Self-Adaptation Crested Porcupine Optimizer (MSCPO) optimized hyperparameters for XGBoost, LightGBM, and Catboost models separately. The fitting, accuracy, and stability of each model in predicting concrete chloride concentration were quantitatively assessed. SHAP was used to explain the best-performing model, and its reliability was supported by microscopic observation results and literature. Results show that identifying and handling outliers enhance model performance. The proposed MSCPO excelled in hyperparameter search, with optimized ensemble models maintaining error within a reasonable range. XGBoost had the best performance, completing hyperparameter search in 45.52 s and achieving an R² of 92.86%. SHAP results aligned closely with experiments and supported existing literature conclusions.

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引用次数: 0

Addressing temperature challenges in machining: Deep-eutectic metalworking fluids and their influence on surface integrity

IF 7.6 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials & Design

Pub Date : 2025-02-05 DOI: 10.1016/j.matdes.2025.113690

Erik Abbá , Alistair Speidel , Zhirong Liao , Donka Novovic , Dragos Axinte

In manufacturing, cutting tools and component integrity are subjected to high-performance thresholds. The role of cutting fluids is pivotal in mitigating heat generation and friction at the tool-workpiece interface. This study explores the application of specifically designed, unconventional, and eco-friendly media, Deep-Eutectic Fluids (DEFs), which provide optimized fluid delivery to the cutting zone, regulating lubrication and cooling, while maintaining the surface integrity of the machined parts. To benchmark DEFs against traditional material removal methods, including dry, and wet (emulsion-based, Hocut 3380) processes, grinding was selected due to its thermal and lubrication demands. The results indicate that DEFs reduce the formation of severely deformed layers by 47% in comparison to conventional water-based coolants exhibiting superior lubricity, yielding more consistent deformation profiles and lower surface roughness. The generated residual stresses are closely comparable to those achieved using water-based metalworking fluids. This was substantiated by micromechanical testing, revealing a coherent failure mechanism at the machined edges for both DEF and wet-cutting media, significantly mitigating the adverse effects of dry machining. These findings highlight DEFs’ potential for industrial-scale adoption as a sustainable alternative in material removal processes, underscoring their capability to enhance process efficiency and environmental sustainability, or as an in-field portable cutting fluid.

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引用次数: 0

Micro-screw extrusion 3D printing of multiscale ternary nanocomposite absorbers – Part I: Comprehensive materials characterization and exceptional microwave absorption performance

IF 7.6 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials & Design

Pub Date : 2025-02-05 DOI: 10.1016/j.matdes.2025.113694

Jiahang Zhang, Dongsheng Li, Mingming Wang

In the context of structural-functional integration, developing advanced microwave-absorbing resin-based composites is an effective solution to combat electromagnetic pollution in military and civilian applications. The use of nanofillers in immiscible polymer blends has gained significant attention for their superior performance. This research employs micro-screw extrusion 3D printing to create a ternary nanocomposite with multi-walled carbon nanotubes, featuring a multi-scale structure and excellent microwave absorption. Nylon 12 and polypropylene serve as matrix materials. By adjusting the geometric structure and component ratios, efficient electromagnetic wave absorption is achieved. Results show that the selective distribution of MWCNTs enhances the composite’s conductivity and dielectric properties. The screw extrusion process proves advantageous for mass production, multi-material compatibility, and online blending, highlighting the nanocomposite’s potential for electromagnetic wave stealth, shielding, and flexible sensing applications.

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引用次数: 0

A volume-preserving model for predicting the geometry of traces produced by drop-on-demand 3D printing

IF 7.6 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials & Design

Pub Date : 2025-02-05 DOI: 10.1016/j.matdes.2025.113687

R. Zamora , F. Faura , J. López , J. Hernández

A model is proposed to predict the geometry of traces generated by molten metal droplet deposition on a flat solid surface. The model also allows the determination of the nozzle displacement that ensures neither droplet buildup nor printed trace discontinuity as a function of impinging droplet size and drop-to-drop and drop-to-substrate contact angles. Experiments performed with Field's alloy droplets and experiments by other authors are used to validate the model. The proposed model significantly improves the predictions for the geometry of the traces obtained using a non-volume-conservative model.

引用次数: 0

Nanophase identification via correlative transmission electron microscopy: A case study of galvannealed advanced high-strength steel

IF 7.6 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials & Design

Pub Date : 2025-02-05 DOI: 10.1016/j.matdes.2025.113696

Alexey Minenkov, Aleksander Brozyniak, Heiko Groiss

The unambiguous identification of nanoscaled phases is an extensively challenging task, which stretches conventional analytical methods to the limit. It holds especially true for nanophases embedded in a matrix with a similar structure and/or chemistry. This hurdle necessitates the use of mutually reinforcing characterization techniques. Here we present the power of correlative transmission electron microscopy utilizing industrial Zn-coated steel with high Si content as a suitable test specimen. Diffusion of Si from the substrate into the coating during annealing leads to the formation of Si-rich nanoprecipitates (NPs) of

30 - 50

nm in size surrounded by a Zn-Fe matrix near the steel/coating interface. Application of our characterization approach, which involves a synergy of high-resolution transmission electron microscopy (TEM) and scanning TEM energy-dispersive X-ray spectroscopy complemented by transmission Kikuchi and precession electron diffraction, allows refining NPs as

D O_{3}

-type structured AlFe₂Si surrounded by the

Γ_{1}

fcc Zn-Fe intermetallic compound. Additionally, the correlation between the structural orientation of the NPs and the matrix was revealed. Considering the dimensions of the entities under study, dependable and high-quality thin TEM sample preparation is of principal importance. We addressed this via low-temperature cutting of specimens with a Xe plasma focused ion beam.

{"title":"Nanophase identification via correlative transmission electron microscopy: A case study of galvannealed advanced high-strength steel","authors":"Alexey Minenkov, Aleksander Brozyniak, Heiko Groiss","doi":"10.1016/j.matdes.2025.113696","DOIUrl":"10.1016/j.matdes.2025.113696","url":null,"abstract":"<div><div>The unambiguous identification of nanoscaled phases is an extensively challenging task, which stretches conventional analytical methods to the limit. It holds especially true for nanophases embedded in a matrix with a similar structure and/or chemistry. This hurdle necessitates the use of mutually reinforcing characterization techniques. Here we present the power of correlative transmission electron microscopy utilizing industrial Zn-coated steel with high Si content as a suitable test specimen. Diffusion of Si from the substrate into the coating during annealing leads to the formation of Si-rich nanoprecipitates (NPs) of <span><math><mn>30</mn><mo>−</mo><mn>50</mn></math></span> nm in size surrounded by a Zn-Fe matrix near the steel/coating interface. Application of our characterization approach, which involves a synergy of high-resolution transmission electron microscopy (TEM) and scanning TEM energy-dispersive X-ray spectroscopy complemented by transmission Kikuchi and precession electron diffraction, allows refining NPs as <span><math><mi>D</mi><msub><mrow><mi>O</mi></mrow><mrow><mn>3</mn></mrow></msub></math></span>-type structured AlFe<sub>2</sub>Si surrounded by the <span><math><msub><mrow><mi>Γ</mi></mrow><mrow><mn>1</mn></mrow></msub></math></span> <em>fcc</em> Zn-Fe intermetallic compound. Additionally, the correlation between the structural orientation of the NPs and the matrix was revealed. Considering the dimensions of the entities under study, dependable and high-quality thin TEM sample preparation is of principal importance. We addressed this via low-temperature cutting of specimens with a Xe plasma focused ion beam.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"251 ","pages":"Article 113696"},"PeriodicalIF":7.6,"publicationDate":"2025-02-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143378622","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Optimizing children's hand orthosis design: A study on contact pressure distribution using FSR sensors

IF 7.6 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials & Design

Pub Date : 2025-02-04 DOI: 10.1016/j.matdes.2025.113679

Dhaval Patel , Ivaylo Mitev , Thomas Rockenbauer , Thomas Antretter , Sandra Schloegl , Margit Lang

The design and comfort of hand orthoses for children are crucial for effective therapeutic outcomes. This research primarily aims to measure the contact force between the hand and orthoses in children under 10 years old and use this data as a loading condition for topology optimization to reduce high-pressure areas, thereby enhancing wear comfort. Force Sensing Resistor (FSR) sensors were employed to record the contact force at 16 specific points on the orthoses using a voltage divider circuit with two different setups: the Teensy 3.5 chip board for 12-bit precision and the Elegoo Mega 2560 chip board for 10-bit precision. These force measurements were compared to existing data from an adult to highlight differences in pressure distribution. Additionally, the study demonstrates the feasibility of integrating precise sensor data into computational models for optimizing medical device designs. While this data could also be utilized in future research for sizing adjustments to optimize the soft padding materials within the orthoses for improved comfort, this aspect is not the primary focus of the current study. The results underscore the importance of developing orthotic designs tailored to pediatric users, informed by precise contact force measurements, to mitigate critical pressure sores and improve overall comfort.

{"title":"Optimizing children's hand orthosis design: A study on contact pressure distribution using FSR sensors","authors":"Dhaval Patel , Ivaylo Mitev , Thomas Rockenbauer , Thomas Antretter , Sandra Schloegl , Margit Lang","doi":"10.1016/j.matdes.2025.113679","DOIUrl":"10.1016/j.matdes.2025.113679","url":null,"abstract":"<div><div>The design and comfort of hand orthoses for children are crucial for effective therapeutic outcomes. This research primarily aims to measure the contact force between the hand and orthoses in children under 10 years old and use this data as a loading condition for topology optimization to reduce high-pressure areas, thereby enhancing wear comfort. Force Sensing Resistor (FSR) sensors were employed to record the contact force at 16 specific points on the orthoses using a voltage divider circuit with two different setups: the Teensy 3.5 chip board for 12-bit precision and the Elegoo Mega 2560 chip board for 10-bit precision. These force measurements were compared to existing data from an adult to highlight differences in pressure distribution. Additionally, the study demonstrates the feasibility of integrating precise sensor data into computational models for optimizing medical device designs. While this data could also be utilized in future research for sizing adjustments to optimize the soft padding materials within the orthoses for improved comfort, this aspect is not the primary focus of the current study. The results underscore the importance of developing orthotic designs tailored to pediatric users, informed by precise contact force measurements, to mitigate critical pressure sores and improve overall comfort.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"251 ","pages":"Article 113679"},"PeriodicalIF":7.6,"publicationDate":"2025-02-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143377046","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

引用次数: 0

Interfacial adhesion between dissimilar thermoplastics fabricated via material extrusion-based multi-material additive manufacturing

IF 7.6 2区材料科学 Q1 MATERIALS SCIENCE, MULTIDISCIPLINARY

Materials & Design

Pub Date : 2025-02-04 DOI: 10.1016/j.matdes.2025.113688

Felix Richter, Dazhong Wu

Multi-material additive manufacturing (MMAM) enables the design of materials with tunable mechanical performance by fabricating multiple dissimilar materials in a single print. MMAM has been utilized to fabricate components with unique mechanical properties for applications such as damage detection, medical devices, sensors, and soft robotics. However, the bonding strength between dissimilar polymeric materials strongly depends on the material combination and is typically lower than the material strength of the constituents. This study investigates the interfacial adhesion between two thermoplastics fabricated via material extrusion (ME)-based MMAM by quantifying the interface bonding strength using mechanical tests and polymer adhesion theory-based correlation analysis. Experimental results showed that the polylactic acid (PLA)-polyethylene terephthalate glycol (PETG), PETG-polycarbonate (PC) and PLA-PC material combinations exhibit bonding strengths that are close to or exceed their constituent’s material strength. Material combinations that include polypropylene (PP) and polyethylene (PE) exhibited bonding strengths of nearly two magnitudes lower than those of PLA-PETG, PETG-PC, and PLA-PC. The microstructural images of the samples showed that the most compatible combinations exhibited a smooth, gradient interface indicating the importance of nano-scale adhesion mechanisms. Based on Hansen solubility parameters and the coefficient of thermal expansion (CTE), we observed the correlation between wettability and physical adsorption, intermolecular diffusion, thermal stress, and the interface bonding strength. The wettability and physical adsorption feature extracted from the solubility parameters showed the highest correlation with the interface bonding strength. Furthermore, we observed that the smaller the difference in solubility parameters and CTE between two thermoplastics fabricated via ME, the more compatible the two thermoplastics are.

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