Pub Date : 2026-01-01DOI: 10.1016/j.matdes.2025.115383
Marcus Lorentzon , Rainer Hahn , Justinas Palisaitis , Helmut Riedl , Lars Hultman , Jens Birch , Naureen Ghafoor
Achieving both high hardness and toughness in protective coatings is a formidable challenge. Here, we harness an original superlattice architecture that synergistically combines Koehler hardening with coherent interfaces to reduce the crack driving forces and enhance toughness, enabling coatings with improved damage tolerance. We engineer epitaxial HfN1.33/Hf0.76Al0.24N1.15 superlattices on MgO(0 0 1) substrates using low-energy, high-flux ion-assisted reactive magnetron sputtering. These superlattices, with bilayer periods ranging from 6 to 20 nm exhibit a unique three-fold superstructure, where each layer forms a three-dimensional checkerboard pattern. HfN1.33 forms a checkerboard period of 7.5 Å from self-organization of Hf-vacancies and N-interstitials, whereas Hf0.76Al0.24N1.15 forms a period of 12.5 Å due to spinodal decomposition. Mechanical testing reveals high hardness (∼36 GPa), matching that of Hf0.76Al0.24N1.15 and exceeding the softer HfN1.33 (∼27 GPa), reflecting interface-driven Koehler strengthening. Micropillar compression tests show distributed cracking along {1 1 0}〈1 1 0〉 slip systems and faster mechanical recovery than Hf0.76Al0.24N1.15 for improved toughness, corroborated by cube-corner indentation fracture analysis, while not reaching the superb toughness and plasticity of HfN1.33. These results demonstrate that epitaxial HfN1.33/Hf0.76Al0.24N1.15 superlattices combine high hardness and strength with good toughness for an improved film damage tolerance.
{"title":"Three-fold superstructured superlattice HfN/HfAlN thin films for improved damage tolerance","authors":"Marcus Lorentzon , Rainer Hahn , Justinas Palisaitis , Helmut Riedl , Lars Hultman , Jens Birch , Naureen Ghafoor","doi":"10.1016/j.matdes.2025.115383","DOIUrl":"10.1016/j.matdes.2025.115383","url":null,"abstract":"<div><div>Achieving both high hardness and toughness in protective coatings is a formidable challenge. Here, we harness an original superlattice architecture that synergistically combines Koehler hardening with coherent interfaces to reduce the crack driving forces and enhance toughness, enabling coatings with improved damage tolerance. We engineer epitaxial HfN<sub>1.33</sub>/Hf<sub>0.76</sub>Al<sub>0.24</sub>N<sub>1.15</sub> superlattices on MgO(0<!--> <!-->0<!--> <!-->1) substrates using low-energy, high-flux ion-assisted reactive magnetron sputtering. These superlattices, with bilayer periods ranging from 6 to 20 nm exhibit a unique three-fold superstructure, where each layer forms a three-dimensional checkerboard pattern. HfN<sub>1.33</sub> forms a checkerboard period of 7.5 Å from self-organization of Hf-vacancies and N-interstitials, whereas Hf<sub>0.76</sub>Al<sub>0.24</sub>N<sub>1.15</sub> forms a period of 12.5 Å due to spinodal decomposition. Mechanical testing reveals high hardness (∼36 GPa), matching that of Hf<sub>0.76</sub>Al<sub>0.24</sub>N<sub>1.15</sub> and exceeding the softer HfN<sub>1.33</sub> (∼27 GPa), reflecting interface-driven Koehler strengthening. Micropillar compression tests show distributed cracking along {1<!--> <!-->1<!--> <!-->0}〈1<!--> <!-->1<!--> <!-->0〉 slip systems and faster mechanical recovery than Hf<sub>0.76</sub>Al<sub>0.24</sub>N<sub>1.15</sub> for improved toughness, corroborated by cube-corner indentation fracture analysis, while not reaching the superb toughness and plasticity of HfN<sub>1.33</sub>. These results demonstrate that epitaxial HfN<sub>1.33</sub>/Hf<sub>0.76</sub>Al<sub>0.24</sub>N<sub>1.15</sub> superlattices combine high hardness and strength with good toughness for an improved film damage tolerance.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"261 ","pages":"Article 115383"},"PeriodicalIF":7.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145939446","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2026-01-01DOI: 10.1016/j.matdes.2025.115361
Guoyang Zhang , Weixuan Lin , Linghuan Guo , Yu Xiang , Luo Wang , Xiaoyu Yan
As a major class of diseases threatening human health and impairing quality of life, bone diseases present significant therapeutic challenges, including low drug bioavailability and inadequate targeting. Nano-drug delivery systems (NDDS) have emerged as a cutting-edge strategy, leveraging their unique advantages in enhancing local drug concentrations, enabling precise targeting, and facilitating intelligent drug release, with evolving material technologies needing systematic sorting for optimized design and application. Focusing on bone disease therapy, this review comprehensively covers the material selection of NDDS, preparation strategies, drug loading methods, and delivery mechanisms. It elaborates on the functional design strategies of NDDS tailored to address the specific needs of bone disease treatment, such as promoting bone formation, angiogenesis, neural regulation, inflammation inhibition, and anti-tumor effects. Additionally, this review analyzes the key challenges hindering the clinical translation of NDDS, while envisioning the transformative potential of intelligent design trends. Overall, this work serves not only as a systematic reference for the precise application and optimization of NDDS in bone disease therapy but also as a handy guide to help researchers organize existing research progress and support clinicians in exploring translational therapeutic strategies—effectively bridging academic research and clinical translation to serve both communities.
{"title":"Application of nano-drug delivery systems in the treatment of bone diseases: Mechanisms, strategies and challenges","authors":"Guoyang Zhang , Weixuan Lin , Linghuan Guo , Yu Xiang , Luo Wang , Xiaoyu Yan","doi":"10.1016/j.matdes.2025.115361","DOIUrl":"10.1016/j.matdes.2025.115361","url":null,"abstract":"<div><div>As a major class of diseases threatening human health and impairing quality of life, bone diseases present significant therapeutic challenges, including low drug bioavailability and inadequate targeting. Nano-drug delivery systems (NDDS) have emerged as a cutting-edge strategy, leveraging their unique advantages in enhancing local drug concentrations, enabling precise targeting, and facilitating intelligent drug release, with evolving material technologies needing systematic sorting for optimized design and application. Focusing on bone disease therapy, this review comprehensively covers the material selection of NDDS, preparation strategies, drug loading methods, and delivery mechanisms. It elaborates on the functional design strategies of NDDS tailored to address the specific needs of bone disease treatment, such as promoting bone formation, angiogenesis, neural regulation, inflammation inhibition, and anti-tumor effects. Additionally, this review analyzes the key challenges hindering the clinical translation of NDDS, while envisioning the transformative potential of intelligent design trends. Overall, this work serves not only as a systematic reference for the precise application and optimization of NDDS in bone disease therapy but also as a handy guide to help researchers organize existing research progress and support clinicians in exploring translational therapeutic strategies—effectively bridging academic research and clinical translation to serve both communities.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"261 ","pages":"Article 115361"},"PeriodicalIF":7.9,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145939451","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-31DOI: 10.1016/j.matdes.2025.115420
Jiapo Wang , Kaiwen Zheng , Jianwei Liang , Yan Peng
This study employs large-scale molecular dynamics simulations to investigate the influence of spherical nanovoids on the nanoindentation response of nickel single crystals. The interaction between nanovoid geometry—varied in size and depth—and the resulting plastic deformation behavior is systematically examined. The results show that nanovoids significantly affect dislocation evolution, acting as dislocation sinks. The absorption capacity increases with nanovoid size and proximity to the free surface. Post-nucleation dislocations propagate toward nanovoids, indicating a spatial coupling between defects and plastic slip activity. Mechanically, nanovoids cause a size- and location-dependent reduction in hardness, with surface-proximal and larger nanovoids having a more pronounced softening effect. Deeply embedded nanovoids show negligible impact. An empirical relation quantifies the hardness degradation based on nanovoid geometry, showing strong agreement with simulation data. These findings provide insights into defect-plasticity interactions and contribute to the design and performance evaluation of nickel-based materials in micro/nanoscale applications.
{"title":"Nanoindentation study on the influence of nanovoid spatial distribution on local plastic deformation behavior","authors":"Jiapo Wang , Kaiwen Zheng , Jianwei Liang , Yan Peng","doi":"10.1016/j.matdes.2025.115420","DOIUrl":"10.1016/j.matdes.2025.115420","url":null,"abstract":"<div><div>This study employs large-scale molecular dynamics simulations to investigate the influence of spherical nanovoids on the nanoindentation response of nickel single crystals. The interaction between nanovoid geometry—varied in size and depth—and the resulting plastic deformation behavior is systematically examined. The results show that nanovoids significantly affect dislocation evolution, acting as dislocation sinks. The absorption capacity increases with nanovoid size and proximity to the free surface. Post-nucleation dislocations propagate toward nanovoids, indicating a spatial coupling between defects and plastic slip activity. Mechanically, nanovoids cause a size- and location-dependent reduction in hardness, with surface-proximal and larger nanovoids having a more pronounced softening effect. Deeply embedded nanovoids show negligible impact. An empirical relation quantifies the hardness degradation based on nanovoid geometry, showing strong agreement with simulation data. These findings provide insights into defect-plasticity interactions and contribute to the design and performance evaluation of nickel-based materials in micro/nanoscale applications.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"262 ","pages":"Article 115420"},"PeriodicalIF":7.9,"publicationDate":"2025-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145898115","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-31DOI: 10.1016/j.matdes.2025.115423
Diana L. Ramírez-Gutiérrez , Enrique Cuan-Urquizo , Armando Roman-Flores
Gradual variations in the structure of metamaterials, known as functionally graded lattices, are increasingly being employed to enhance material performance across various engineering fields. Breaking symmetry and uniformity has enhanced functionality by improving mechanical properties like stiffness, energy absorption and unique deformation mechanisms. The present study introduces a novel design framework for creating a wide range of graded lattices made of curved constituent elements parameterized with sinusoids. This design approach allows the gradation of horizontal and vertical constituent elements independently. Specimens were additively manufactured to experimentally characterize the mechanical properties, deformation modes, and energy absorption under quasi-static compression tests. These experimental results were compared with nonlinear finite element models, resulting in good agreement. The graded lattices generated result in predictable deformation, smoother transitions between elastic and plastic deformation, higher strength and increased energy absorption compared to their uniform counterparts. Varying only one design parameter resulted in a 33% increase in the effective Young’s modulus, while maintaining the variation of volume fraction with 2%. This study demonstrates the potential of this design framework to obtain a wide design space for a desired mechanical performance while controlling the directionality dependence of the properties in the two main axes.
{"title":"Functionally graded sinusoid-based metamaterials: Towards tailoring effective mechanical properties and deformation modes with a single design parametric function","authors":"Diana L. Ramírez-Gutiérrez , Enrique Cuan-Urquizo , Armando Roman-Flores","doi":"10.1016/j.matdes.2025.115423","DOIUrl":"10.1016/j.matdes.2025.115423","url":null,"abstract":"<div><div>Gradual variations in the structure of metamaterials, known as functionally graded lattices, are increasingly being employed to enhance material performance across various engineering fields. Breaking symmetry and uniformity has enhanced functionality by improving mechanical properties like stiffness, energy absorption and unique deformation mechanisms. The present study introduces a novel design framework for creating a wide range of graded lattices made of curved constituent elements parameterized with sinusoids. This design approach allows the gradation of horizontal and vertical constituent elements independently. Specimens were additively manufactured to experimentally characterize the mechanical properties, deformation modes, and energy absorption under quasi-static compression tests. These experimental results were compared with nonlinear finite element models, resulting in good agreement. The graded lattices generated result in predictable deformation, smoother transitions between elastic and plastic deformation, higher strength and increased energy absorption compared to their uniform counterparts. Varying only one design parameter resulted in a 33% increase in the effective Young’s modulus, while maintaining the variation of volume fraction with <span><math><mo><</mo></math></span>2%. This study demonstrates the potential of this design framework to obtain a wide design space for a desired mechanical performance while controlling the directionality dependence of the properties in the two main axes.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"262 ","pages":"Article 115423"},"PeriodicalIF":7.9,"publicationDate":"2025-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145941190","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-31DOI: 10.1016/j.matdes.2025.115427
Shihao Su , Wenyuan Wang , Sheng Zhang , Fengchao Wu , Fan Liu , Yang Liu , Yong Liu , Liang Shen , Lei Lu , Bin Su , Yong Xu , Tao Fa
Irradiation can cause severe property degradation of materials (i.e., radioactive aging), which has drawn general interest in both scientific research and engineering applications. In nuclear areas, this is significantly important due to many nuclear materials being radioactive or exposed to radiation environments. Although the basic process of the self-irradiation of actinides and their derivatives has been studied, there is still much that remains elusive, especially for Pu-Ga alloys, one of the most mysterious nuclear materials. Here, we utilize molecular dynamics simulations to study the influence of the incident angle of the U nucleus on the self-irradiation of -phase Pu-Ga alloys, also concerning the effect of Ga concentration in the alloys. The generation of defects shows obvious dependence on the U incident angles, where the maximum and ultimate numbers of defects change up to 59% and 38%, respectively. Besides, the ultimate local atomic structures of the materials are also affected. Different U incident angles lead to different collision kinematics and energy transfer efficiencies, which subsequently cause cascade collisions with different paths and scales. Specifically, the coupling of thermal vibrations and geometric alignment in certain directions leads to high variability in defect production. The self-irradiation of -phase Pu-Ga alloys with a series of Ga concentrations (ranging from 2 to 7 at. %) is also studied, and the ultimate defect number is found to be the smallest for the alloys with the middle concentration of 5 at. %. This work shows the importance of considering the irradiation angle and element content for the primary damage formation underlying radioactive aging of nuclear materials, which will be useful for the development of strategies to manage aged nuclear materials.
{"title":"Radiation damage in δ-phase Pu-Ga alloys","authors":"Shihao Su , Wenyuan Wang , Sheng Zhang , Fengchao Wu , Fan Liu , Yang Liu , Yong Liu , Liang Shen , Lei Lu , Bin Su , Yong Xu , Tao Fa","doi":"10.1016/j.matdes.2025.115427","DOIUrl":"10.1016/j.matdes.2025.115427","url":null,"abstract":"<div><div>Irradiation can cause severe property degradation of materials (i.e., radioactive aging), which has drawn general interest in both scientific research and engineering applications. In nuclear areas, this is significantly important due to many nuclear materials being radioactive or exposed to radiation environments. Although the basic process of the self-irradiation of actinides and their derivatives has been studied, there is still much that remains elusive, especially for Pu-Ga alloys, one of the most mysterious nuclear materials. Here, we utilize molecular dynamics simulations to study the influence of the incident angle of the U nucleus on the self-irradiation of <span><math><mtext>δ</mtext></math></span>-phase Pu-Ga alloys, also concerning the effect of Ga concentration in the alloys. The generation of defects shows obvious dependence on the U incident angles, where the maximum and ultimate numbers of defects change up to 59% and 38%, respectively. Besides, the ultimate local atomic structures of the materials are also affected. Different U incident angles lead to different collision kinematics and energy transfer efficiencies, which subsequently cause cascade collisions with different paths and scales. Specifically, the coupling of thermal vibrations and geometric alignment in certain directions leads to high variability in defect production. The self-irradiation of <span><math><mtext>δ</mtext></math></span>-phase Pu-Ga alloys with a series of Ga concentrations (ranging from 2 to 7 at. %) is also studied, and the ultimate defect number is found to be the smallest for the alloys with the middle concentration of 5 at. %. This work shows the importance of considering the irradiation angle and element content for the primary damage formation underlying radioactive aging of nuclear materials, which will be useful for the development of strategies to manage aged nuclear materials.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"262 ","pages":"Article 115427"},"PeriodicalIF":7.9,"publicationDate":"2025-12-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145940605","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-30DOI: 10.1016/j.matdes.2025.115418
Haojie Liu , Zhuorong Zhan , Yan Wang , Na Zhao , Caihong Wu , Yan Yang , ChingTso Hsu , Xiaoliang Wang , Junqing Ma
Effective bone defect repair requires coordinated osteogenesis and angiogenesis while simultaneously combating infection and reactive oxygen species (ROS). However, multifunctional 3D-printed Ti6Al4V scaffolds capable of precisely and differentially releasing bioactive agents remain insufficiently exploration. Given that nanotubes with tailored morphologies exhibit excellent surface modification potential and drug loading capacity, we developed a multifunctional composite controlled-release system (Zn@dTNT/Ce-TA) by coating zinc (Zn)-loaded dumbbell-like titanium dioxide nanotube arrays (dTNT) with cerium (Ce)–tannic acid (TA) metal–phenolic networks (MPNs) to enhance bone reconstruction. This composite scaffold enables sustained and controlled release of Zn and Ce ions, thereby promoting coordinated osteogenesis and angiogenesis while providing antibacterial and antioxidative protection. Furthermore, Zn@dTNT/Ce-TA effectively scavenges both mitochondrial and exogenous ROS, stabilizing the microenvironment at bone defect sites. Overall, this study proposes a promising strategy for reparing critical-sized bone defects and managing ROS-associated bone diseases, offering a valuable direction for future bone tissue engineering.
{"title":"Multifunctional zinc@dTNT/cerium-tannic acid composite system for controlled release of metal micronutrients to enhance bone reconstruction","authors":"Haojie Liu , Zhuorong Zhan , Yan Wang , Na Zhao , Caihong Wu , Yan Yang , ChingTso Hsu , Xiaoliang Wang , Junqing Ma","doi":"10.1016/j.matdes.2025.115418","DOIUrl":"10.1016/j.matdes.2025.115418","url":null,"abstract":"<div><div>Effective bone defect repair requires coordinated osteogenesis and angiogenesis while simultaneously combating infection and reactive oxygen species (ROS). However, multifunctional 3D-printed Ti6Al4V scaffolds capable of precisely and differentially releasing bioactive agents remain insufficiently exploration. Given that nanotubes with tailored morphologies exhibit excellent surface modification potential and drug loading capacity, we developed a multifunctional composite controlled-release system (Zn@dTNT/Ce-TA) by coating zinc (Zn)-loaded dumbbell-like titanium dioxide nanotube arrays (dTNT) with cerium (Ce)–tannic acid (TA) metal–phenolic networks (MPNs) to enhance bone reconstruction. This composite scaffold enables sustained and controlled release of Zn and Ce ions, thereby promoting coordinated osteogenesis and angiogenesis while providing antibacterial and antioxidative protection. Furthermore, Zn@dTNT/Ce-TA effectively scavenges both mitochondrial and exogenous ROS, stabilizing the microenvironment at bone defect sites. Overall, this study proposes a promising strategy for reparing critical-sized bone defects and managing ROS-associated bone diseases, offering a valuable direction for future bone tissue engineering.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"262 ","pages":"Article 115418"},"PeriodicalIF":7.9,"publicationDate":"2025-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145898117","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-30DOI: 10.1016/j.matdes.2025.115415
Fei Lv , Pengbo Gao , Xuesong Gao , Meng Xiao , Deqiao Xie , Jun Zhou , Kai Wang
High-strength aluminum alloys are attractive for aerospace but suffer fatigue failure from porosity introduced during laser powder bed fusion (LPBF). In this study, a Sc-containing alloy was fabricated to near-full density, and the effects of enhancement aging (EA) and laser in-situ re-melting (RE) on microstructure, tensile, and high-cycle fatigue (HCF) properties were compared with the as-built (AB) condition. All samples exhibited a bi-modal grain structure of fine equiaxed grains at molten pool boundaries and coarse columnar grains inside the pools. XRD/TEM revealed coherent AlsSc precipitates that refined grains and improved stability. EA achieved the highest tensile strength (574 MPa) due to secondary Al3Sc precipitation and Mn-rich solid solution, while RE gave slightly lower strength (545 MPa) but superior fatigue strength (115 MPa at 107 cycles). Three-dimensional (3D) μCT showed that irregular pores > 20 μm persisted in AB and EA samples as fatigue crack initiation sites, whereas RE markedly reduced their number and size. Thermal modeling indicated that RE stabilized the molten pool, suppressed keyhole instabilities, and promoted pore elimination. Acting as an integrated heat treatment, laser in-situ re-melting improves fatigue resistance while simplifying the LPBF process.
{"title":"Laser in-situ re-melting induced porosity control and fatigue improvement in LPBFed high-strength Sc-containing aluminum alloy","authors":"Fei Lv , Pengbo Gao , Xuesong Gao , Meng Xiao , Deqiao Xie , Jun Zhou , Kai Wang","doi":"10.1016/j.matdes.2025.115415","DOIUrl":"10.1016/j.matdes.2025.115415","url":null,"abstract":"<div><div>High-strength aluminum alloys are attractive for aerospace but suffer fatigue failure from porosity introduced during laser powder bed fusion (LPBF). In this study, a Sc-containing alloy was fabricated to near-full density, and the effects of enhancement aging (EA) and laser in-situ re-melting (RE) on microstructure, tensile, and high-cycle fatigue (HCF) properties were compared with the as-built (AB) condition. All samples exhibited a bi-modal grain structure of fine equiaxed grains at molten pool boundaries and coarse columnar grains inside the pools. XRD/TEM revealed coherent AlsSc precipitates that refined grains and improved stability. EA achieved the highest tensile strength (574 MPa) due to secondary Al<sub>3</sub>Sc precipitation and Mn-rich solid solution, while RE gave slightly lower strength (545 MPa) but superior fatigue strength (115 MPa at 10<sup>7</sup> cycles). Three-dimensional (3D) μCT showed that irregular pores > 20 μm persisted in AB and EA samples as fatigue crack initiation sites, whereas RE markedly reduced their number and size. Thermal modeling indicated that RE stabilized the molten pool, suppressed keyhole instabilities, and promoted pore elimination. Acting as an integrated heat treatment, laser in-situ re-melting improves fatigue resistance while simplifying the LPBF process.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"262 ","pages":"Article 115415"},"PeriodicalIF":7.9,"publicationDate":"2025-12-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145898114","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-29DOI: 10.1016/j.matdes.2025.115407
Peter Ibrahim , Konstantinos Liogas , Muhammad Naeem , Alexander M. Korsunsky , Richard J. Moat , Moataz M. Attallah
β-Ti alloys have been recognised as promising candidates for variety of applications such as biomedical implants and aerospace morphing wings. Alloy systems such as Ti-Nb-Ta-Zr manufactured by Laser Powder Bed Fusion offer great opportunities for custom parts and design optimisation to best fit the application. In this study, in-situ tensile testing of built Ti-34Nb-13Ta-5Zr-0.3O samples was conducted with the aid of Synchrotron X-ray diffraction to investigate the effect of heat treatment on the deformation behaviour. The analysis of β-phase in different conditions showed increasing elastic moduli for each lattice plane. This modulus variations are related to elimination of segregated elements and the increasing alloy homogeneity during solution treatment. Also, α-needles developed during aging had a hardening effect. Aged condition showed stress partitioning between α and β planes where the β phase failed while α phase kept up to higher stress levels. The analysis showed the high amount of dislocation in the as-built samples due to the high residual strains, which were relieved by solution treatment, explaining the increased macro-ductility of the solution treated samples. The study highlights the role of the heat treatment in controlling the macro scale mechanical behaviour through impacting both the microstructure and sub-structure.
{"title":"Rationalising the effect of post-additive manufacturing heat treatment on the deformation behaviour in Ti-34Nb-13Ta-5Zr-0.3O alloy using synchrotron diffraction","authors":"Peter Ibrahim , Konstantinos Liogas , Muhammad Naeem , Alexander M. Korsunsky , Richard J. Moat , Moataz M. Attallah","doi":"10.1016/j.matdes.2025.115407","DOIUrl":"10.1016/j.matdes.2025.115407","url":null,"abstract":"<div><div>β-Ti alloys have been recognised as promising candidates for variety of applications such as biomedical implants and aerospace morphing wings. Alloy systems such as Ti-Nb-Ta-Zr manufactured by Laser Powder Bed Fusion offer great opportunities for custom parts and design optimisation to best fit the application. In this study, in-situ tensile testing of built Ti-34Nb-13Ta-5Zr-0.3O samples was conducted with the aid of Synchrotron X-ray diffraction to investigate the effect of heat treatment on the deformation behaviour. The analysis of β-phase in different conditions showed increasing elastic moduli for each lattice plane. This modulus variations are related to elimination of segregated elements and the increasing alloy homogeneity during solution treatment. Also, α-needles developed during aging had a hardening effect. Aged condition showed stress partitioning between α and β planes where the β phase failed while α phase kept up to higher stress levels. The analysis showed the high amount of dislocation in the as-built samples due to the high residual strains, which were relieved by solution treatment, explaining the increased macro-ductility of the solution treated samples. The study highlights the role of the heat treatment in controlling the macro scale mechanical behaviour through impacting both the microstructure and sub-structure.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"262 ","pages":"Article 115407"},"PeriodicalIF":7.9,"publicationDate":"2025-12-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145974397","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
This study reviews the transformability potential of the Material Extrusion (MEX) process as a possible contributor to circular manufacturing by facilitating plastic upcycling and biomass valorization. MEX makes the use of recycled thermoplastics as feedstock and their blending with reinforcement or functionalizing fillers feasible, opening ground-breaking routes to the development of sustainable composite materials. Biomass waste, as filler, can reinforce the thermoplastic matrix but also provide antibacterial, regenerative, and wound-healing properties to the composites. Examples of already developed materials, potential applications, and a focus on four thermoplastic materials (i.e., Polylactic Acid − PLA, Polyhydroxyalkanoates − PHAs, Polycaprolactone − PCL, and Polyvinyl alcohol − PVA) are provided. The discussion focuses on the Fused Deposition Modeling technique and includes the Fused Granulate Fabrication technique. The challenges persisting in material design, fabrication, and printing, limiting functionality and performance, are highlighted to stimulate further research into optimizing all steps of the upcycling process. The contribution of Artificial Intelligence (AI) in pursuing this target, by supporting MEX-related workflows, from optimizing printing parameters and predicting material performance to enhancing the reliability of recycled feedstocks and enabling more effective circular material cycles, is also analyzed.
{"title":"Upcycling potential of the material extrusion process: a focus on the fused deposition modeling and beyond","authors":"Raffaele Pugliese , Mushtaq Alam Madar Saheb , Stefano Cantella , Silvia Badini , Carlotta Bollati , Carmen Lammi , Serena Graziosi","doi":"10.1016/j.matdes.2025.115408","DOIUrl":"10.1016/j.matdes.2025.115408","url":null,"abstract":"<div><div>This study reviews the transformability potential of the Material Extrusion (MEX) process as a possible contributor to circular manufacturing by facilitating plastic upcycling and biomass valorization. MEX makes the use of recycled thermoplastics as feedstock and their blending with reinforcement or functionalizing fillers feasible, opening ground-breaking routes to the development of sustainable composite materials. Biomass waste, as filler, can reinforce the thermoplastic matrix but also provide antibacterial, regenerative, and wound-healing properties to the composites. Examples of already developed materials, potential applications, and a focus on four thermoplastic materials (i.e., Polylactic Acid − PLA, Polyhydroxyalkanoates − PHAs, Polycaprolactone − PCL, and Polyvinyl alcohol − PVA) are provided. The discussion focuses on the Fused Deposition Modeling technique and includes the Fused Granulate Fabrication technique. The challenges persisting in material design, fabrication, and printing, limiting functionality and performance, are highlighted to stimulate further research into optimizing all steps of the upcycling process. The contribution of Artificial Intelligence (AI) in pursuing this target, by supporting MEX-related workflows, from optimizing printing parameters and predicting material performance to enhancing the reliability of recycled feedstocks and enabling more effective circular material cycles, is also analyzed.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"262 ","pages":"Article 115408"},"PeriodicalIF":7.9,"publicationDate":"2025-12-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145974503","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-12-29DOI: 10.1016/j.matdes.2025.115411
Jingyi Yang , Zhong You , Maozhou Meng , Tom Tosdevin , Alistair G.L. Borthwick , John R. Chaplin , Bohan Chen , Siming Zheng , Martyn Hann , Shanshan Cheng , Xinyu Wang , Krishnendu Puzhukkil , Malcolm Cox , Kieran Monk , Deborah M. Greaves
Ocean waves offer sustainable power yet the design of efficient and durable wave energy converters (WECs) remains challenging. We focus on a WEC that harvests energy from chamber volume change as two bottom-hinged plates open and close with passing wave troughs and crests, driving a turbine generator. For the first time, we present an origami-inspired enclosed WEC whose plates are linked by rigid pleats and confined membrane regions. Unlike traditional flexible WECs that connect the flaps with elastic membranes that stretch, our design achieves predictable cyclic motion through origami folding mechanisms. Using an analytical design method, we optimize dimensions of the pleats and membranes that keep membrane strain minimal during operation. The analytical design is confirmed by finite element analyses, which indicates negligible membrane strain under normal operation, therefore long fatigue life. Tests on a 1:160 scale prototype achieve a capture width ratio of 0.35 and demonstrate robustness under irregular waves and deliberate misalignment. Our WEC design allows the power take-off (PTO) system to be positioned above sea level, ensuring the PTO system operates in air and remains unaffected even if sealing fails. These results demonstrate the potential of origami-inspired WECs as viable and scalable approaches to wave energy harvesting.
{"title":"Harnessing waves with folds: a flexible origami-inspired wave energy converter","authors":"Jingyi Yang , Zhong You , Maozhou Meng , Tom Tosdevin , Alistair G.L. Borthwick , John R. Chaplin , Bohan Chen , Siming Zheng , Martyn Hann , Shanshan Cheng , Xinyu Wang , Krishnendu Puzhukkil , Malcolm Cox , Kieran Monk , Deborah M. Greaves","doi":"10.1016/j.matdes.2025.115411","DOIUrl":"10.1016/j.matdes.2025.115411","url":null,"abstract":"<div><div>Ocean waves offer sustainable power yet the design of efficient and durable wave energy converters (WECs) remains challenging. We focus on a WEC that harvests energy from chamber volume change as two bottom-hinged plates open and close with passing wave troughs and crests, driving a turbine generator. For the first time, we present an origami-inspired enclosed WEC whose plates are linked by rigid pleats and confined membrane regions. Unlike traditional flexible WECs that connect the flaps with elastic membranes that stretch, our design achieves predictable cyclic motion through origami folding mechanisms. Using an analytical design method, we optimize dimensions of the pleats and membranes that keep membrane strain minimal during operation. The analytical design is confirmed by finite element analyses, which indicates negligible membrane strain under normal operation, therefore long fatigue life. Tests on a 1:160 scale prototype achieve a capture width ratio of 0.35 and demonstrate robustness under irregular waves and deliberate misalignment. Our WEC design allows the power take-off (PTO) system to be positioned above sea level, ensuring the PTO system operates in air and remains unaffected even if sealing fails. These results demonstrate the potential of origami-inspired WECs as viable and scalable approaches to wave energy harvesting.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"262 ","pages":"Article 115411"},"PeriodicalIF":7.9,"publicationDate":"2025-12-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145940670","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}