Design Of Structural Materials Research Articles

Industrial production of asymmetric wettability patterned fabric for efficient atmospheric water harvesting

While harvesting water from the atmosphere is considered as a promising technology to address the increasing issue of water scarcity, its wide applications are still limited by the difficulty in mass production of water harvesting materials. Here, an industrial-producible asymmetric wettability patterned fabric (AWPF) with high water harvesting capacity is developed using a continuous and low-cost weaving technology. Four textile patterns are developed for high-efficiency atmospheric water harvesting. The alternating patterned surface in AWPF is constructed with hydrophilic bumps and hydrophobic grooves using one set of green fluorine-free superhydrophobic polyester warp yarns and two sets of superhydrophobic polyester/hydrophilic viscose weft yarns. We optimized the water collection performance of the single-sided AWPF by spraying co-MBAA-DVB superhydrophobic material on the back of the AWPF to construct a wetting gradient, that is, double-sided AWPF. The double-sided AWPF shows a strong water harvesting capacity of 2840.2 mg·6h−1·cm−2, which increased the water harvesting efficiency by 43.2 % compared with the unoptimized single-sided AWPF. To reduce the pressure drop, 6 mm wide the double-sided AWPF was designed, resulting in a water harvesting capacity that is 1.23 times higher than that of without cutting. This advanced industrialized weaving technology with an asymmetric fabric structure design holds great potential for substantial water harvesting.

Microstructural material design of pearlitic steel lamella for desired mechanical properties

Designing materials for a targeted mechanical property is a complex problem due to its structure and property relationship nature, traditionally relying on experimental methods. Computational approaches offer a promising alternative, but they are often computationally intensive. This limits their applicability for solving the goal-based structure design problem. This study focuses on the design of microstructure to achieve specific mechanical properties by combining generative adversarial networks, deep neural networks, and genetic algorithm optimization techniques. In this work to demonstrate the effectiveness of the proposed approach we select a widely used pearlitic steel lamella microstructure where the phase fraction of ferrite and cementite and the lamella distribution significantly influence the strength and ductility. A method for designing the pearlite microstructure features for the targeted mechanical properties, such as yield strength (σy), ultimate strength (σut), and fracture strain (εf) is developed by applying inverse microstructure design techniques to achieve the targeted mechanical properties, specifically in fully pearlitic steel materials. The findings hold great promise, particularly when coupled with additive manufacturing, in offering an efficient and versatile framework for structural materials design for targeted material applications.

Inverse Identification of Constituent Elastic Parameters of Ceramic Matrix Composites Based on Macro–Micro Combined Finite Element Model

Accurate material performance parameters are the prerequisite for conducting composite material structural analysis and design. However, the complex multiscale structure of ceramic matrix composites (CMCs) makes it extremely difficult to accurately obtain their mechanical performance parameters. To address this issue, a CMC micro-scale constituents (fiber bundles and matrix) elastic parameter inversion method was proposed based on the integration of macro–micro finite element models. This model was established based on the μCT scan data of a plain-woven CMC tensile specimen using the chemical vapor infiltration (CVI) process, which could reflect the real microstructure and surface morphology characteristics of the material. A BP neural network was used to predict the multiscale stiffness, considering the influence of the porous structure on the macroscopic stiffness of the material. The inversion process of the constituent elastic parameters was established using the trust-region algorithm combined with an improved error function. The inversion results showed that this method could accurately invert the CMC constituent elastic parameters with excellent robustness and anti-noise performance. Under four different degrees of deviation in the initial iteration conditions, the inversion error of all parameters was within 1%, and the maximum inversion error was only 2.16% under a 10% high noise level.

Ultrasensitive and Stretchable Strain Sensors Based on Laser-Induced Graphene With ZnO Nanoparticles.

Laser-induced graphene (LIG) has attracted considerable attention for its use in flexible and stretchable sensors, owing to its electrical/mechanical properties and scalable fabrication processes. Although laser scanning facilitates the formation of LIG and its strain sensor, the strain-sensing sensitivity enhancement of LIG remains limited by the material's properties and structural design. In this study, we demonstrate a substantial improvement in sensitivity that was achieved by fabricating a LIG using ZnO nanoparticle (NP)-assisted photothermal enhancement. The results show that ZnO NPs selectively reduce the threshold fluence needed to convert polyimide (PI) into LIG. By transferring the LIG formed on PI to poly(dimethylsiloxane), we fabricate a stretchable strain sensor with ultrahigh sensitivity and a gauge factor of 1214 at 10% strain, which is approximately 60 times higher than the gauge factor without ZnO NPs. Using the selective graphenization properties of LIG, a flexible, dual-sided integrated sensor sheet that is equipped with flexible strain and ultraviolet (UV) sensors is demonstrated. This sheet enables simultaneous monitoring of UV intensity and joint bending angles of sports wearable devices. We validated the developed sensors by attaching them to a runner's body to monitor and simulate forefoot and heel strikes, demonstrating the sensor's ultrahigh sensitivity and long-term stability without the need for a camera. These findings highlight the potential of the proposed method for developing multifunctional sensor applications with ultrahigh sensitivity and stability.

New Materials and Structures: Anti-Escape Trap Net for Trapping Eucryptorrhynchus brandti (Harold, 1880) (Coleoptera: Curculionidae)

The weevil Eucryptorrhynchus brandti (Harold, 1880), a wood-boring pest of Ailanthus altissima (Mill.) Swingle, has caused significant ecological damage and economic loss in China. Physical control was effective against the related species Eucryptorrhynchus scrobiculatus (Motschulsky). One type of trunk trap net controlled the adult weevil population through blocking and trapping. However, the effectiveness of this device was compromised by their tendency to escape when encountering such trapping nets. Therefore, it is crucial to enhance and optimize both the material composition and structural design of trap nets to enhance weevil capture rates by mitigating escape behavior. In this study, we compared the capture efficacy of an anti-escape trap net (AETN) with novel materials (Velcro) and a double-layer trap net (DLTN). The results indicate that the mean recapture rate of AETNs (50%) was significantly higher than that of DLTNs (3%) in laboratory tests. The total number of E. brandti captured using AETNs was 11 times higher than that of DLTNs in field marker recapture tests and 4 times higher in capture tests on field populations. The new AETN structures could effectively prevent the escape behavior of E. brandti and capture weevils. The use of Velcro made the AETN easier to manufacture, more convenient to use, and less costly. Overall, the AETN is an economical and environmentally friendly physical control device.

Dynamic response mechanism of layered coatings under impacts: Insights from the perspective of stress wave

Precision machining operations often lead to the failure of protective coatings on cutting tools due to common issues such as cracking, delamination, and peeling from cyclic impacts. While material selection and structural design are crucial for enhancing impact resistance, they primarily focus on static performance with limited consideration from the dynamic sights. This paper presents a novel dynamic design method for coatings, viewed through the lens of stress waves. We investigate the propagation behavior of stress waves in TaN/TiN and CrN/TiN coatings with layered structures. Our findings indicate that the attenuation of stress waves is dominated by the physical properties on both sides of the interface and the stride length. For interfaces with similar physical properties, the attenuation of stress waves is insensitive to the stride length, while for interfaces with different physical properties, the attenuation is regulated by the ratio of single-layer thickness to the full width at half maximum of the stress wave. These insights offer a strategy for extending the life of coatings and improving process safety under dynamic shocks.

Computational design of 4D printed shape morphing lattices undergoing large deformation

Abstract In 4D Printing, active materials are embedded in structures such that the application of an external stimulus, usually coming from the environment, results in a structural response. To design structures that achieve a targeted shape change for a defined stimulus, also known as shape morphing, the material distribution and structure needs to be tuned. However, the computational design of such material distributions and structures is a challenging task and remains, despite recent advances, unable to fully leverage the entire design freedom offered by state-of-the-art 4D printing technology. Notable gaps concern the handling of large and complex deformations, the high computational cost, and the exploration of the design space by the generation of alternative solutions. In this article, a method is presented to fill this gap. First, an artificial neural net is trained that represents a deformation map that occurs during actuation. Then, a shape morphing truss is designed that achieves this deformation during actuation. The method is used to solve four shape morphing problems, where superior capabilities are demonstrated in terms of magnitude and complexity of deformations that can be handled, efficient generation of alternative solutions and versatility. Due to these capabilities, the method enables exploration of the full potential of 4D printing technology to create stimuli-responsive, multifunctional structures.

Graded Nanotexturing Architectural Wearable Triboelectric Sensor for Programmable Haptic Exploration.

Emulating biological perception mechanisms to construct intelligent sensing devices and systems represents a paradigm for promoting human-computer interaction in the Internet of Everything era. Nonetheless, developing highly sensitive, real-time sensing and rapidly integrated intelligent interaction units remains a challenging and time-consuming endeavor. This study employs a low-temperature glow discharge technique to rapidly fabricate graded nanotexturing architectural triboelectric nanopaper, upon which wearable triboelectric sensors for real-time tactile detection are designed. The structure enhances the contact area under an external force. Additionally, the Z-stacking structure design enables the sensor to achieve a remarkable sensitivity of 10.3 kPa-1 and a rapid response time of 52 ms. Furthermore, a tactile sensor array was designed to demonstrate the triboelectric sensor's ability to recognize characteristic pressures. With programmable machine learning techniques, the object recognition rate reached 97%. This study supports material structural design across disciplines, laying a solid foundation for the rapid fabrication and integration of transient wearable electronics.

Design and implementation of corrosion-resistant multitasking cell stainers.

Compared with machine staining, traditional manual staining faces various problems, such as a low preparation success rate, low efficiency, and harm to the human body due to corrosive gases. Therefore, a stainer that is of low cost, has strong corrosion resistance, and is suitable for small-batch preparation should be developed. In this study, by choosing a rotary scheme as the structural basis, a reusable container cover and a master-slave manipulator cooperation scheme are developed, which greatly improve the space utilization rate. Through material selection and structural design, in the designed stainer, effective protection against strong acids with high volatility and permeability is realized, thereby eliminating the corrosion issue. Using the designed splitting-running algorithm for the dyeing procedure, simultaneous multistaining is realized, which significantly improves the staining efficiency. Compared with large-sized stainers, the cost of the proposed stainer is very low, which will help popularize early screening for cervical cancer in low- and middle-income countries.

A Stable Perovskite Sensitized Photonic Crystal P-N Junction with Enhanced Photoelectrochemical Hydrogen Production.

The slow photon effect in inverse opal photonic crystals represents a promising approach to manipulate the interactions between light and matter through the design of material structures. This study introduces a novel ordered inverse opal photonic crystal (IOPC) sensitized with perovskite quantum dots (PQDs), demonstrating its efficacy for efficient visible-light-driven H2 generation via water splitting. The rational structural design contributes to enhanced light harvesting. The sensitization of the IOPC with PQDs improves optical response performance and enhances photocatalytic H2 generation under visible light irradiation compared to the IOPC alone. The designed photoanode exhibits a photocurrent density of 3.42 mA cm-2 at 1.23 V vs RHE. This work advances the rational design of visible light-responsive photocatalytic heterostructure materials based on wide band gap metal oxides for photoelectrochemical applications.

Three-dimensional porous SiC/BDD electrode with long-term robustness and enhanced electrochemical degradation performance for refractory organic pollutants

Boron-doped diamond (BDD) electrodes with a three-dimensional (3D) porous network structure can overcome the mass transfer limitations and increase substantially the utilization rate of active oxygen species. Nonetheless, the 3D porous network structure was invariably built using metallic substrates, which inherently have inferior stability because of their non-corrosion resistance and the severe thermal mismatch between BDD films and substrates. Herein, we reported, for the first time, the use of a commercially porous silicon carbide (SiC) as the substrate to construct a 3D SiC/BDD electrode to simultaneously alleviate the problematics of substrate corrosion and thermal mismatch. This novel electrode exhibited a long-term service lifetime of 800 h in 3 M H2SO4 under the current density of 50 mA cm−2, over 500 times longer than the conventional metallic substrate-based BDD electrodes. The optimum p-SiC/BDD electrode exhibited a high oxygen evolution potential of 2.04 V vs. SHE, a low charge transfer resistance of 18.4 Ω, a high mass transfer coefficient of 2.78 × 10−5 m s−1, and a thin diffusion layer thickness of 25.2 μm. The proposed electrode had a threefold larger pseudo-first-order reaction rate constant than a flat BDD electrode, although it consumed just a fourth of the latter’s electric energy. The superior performance was attributable to an increased mass transfer rate confirmed by computational fluid dynamics (CFD) simulations as well as a high yield of reactive oxygen species verified by electron spin resonance (ESR). Furthermore, the proposed SiC/BDD electrode could work effectively under different water matrices in the presence of diverse salt electrolytes, thus paving a new avenue for the structure design of robust non-active anode materials.

Ferroelectric tungsten bronze-based ceramics with high-energy storage performance via weakly coupled relaxor design and grain boundary optimization

A multiscale regulation strategy has been demonstrated for synthetic energy storage enhancement in a tetragonal tungsten bronze structure ferroelectric. Grain refining and second-phase precipitation (perovskite phase) are introduced in the BaSrTiNb2-xTaxO9 ceramics by regulating the composition and sintering process. Disordered polarization and distribution, chemical inhomogeneity, and insulating boundary layers are achieved to provide the fundamental structural origin of the relaxation characteristic, high breakdown strength, and superior energy storage performance. Thus, an ultrahigh energy storage density of 12.2 J cm−3 with an low energy consumption was achieved at an electric field of 950 kV cm−1. This is the highest known energy storage performance in tetragonal tungsten bronze-based ferroelectric. Notably, this ceramic shows remarkable stability over frequency, temperature, and cycling electric fields. This work brings new material candidates and structure design for developing of energy storage capacitors apart from the predominant perovskite ferroelectric ceramics.

Unveiling the Future of Safety: Cutting-Edge Simulation Testing of e-Kart Bumpers

Abstract This research project proves the importance of simulation technology in developing safe and efficient components for electric Go-Kart and how this approach could impact the future of automotive design and engineering. The development of electric Go-Kart present unique challenges in ensuring safety and performance, given the increasing demand for eco-friendly mobility solutions in motorsports. As the adoption of the electric vehicles grow, the importance of designing robust and reliable safety components, such as bumpers, become critical to protect drivers and enhance vehicle durability. While previous studies have explored Go-Kart safety and performance, they often relied on traditional testing methods that are time-consuming and limited in their ability to simulate complex crash scenarios. Moreover, many studies have not fully addressed the specific challenges associated with the unique dynamics of electric Go-Kart. This research fills these gaps by focusing on testing electric Go-Kart bumpers through advanced computer simulations used to thoroughly examine various crash and impact scenarios to assess the reliability and durability of the front, side and rear bumpers to improve safety and performance. The results of the stress analysis carried out on the electric Go-Kart body showed that the electric go-kart body experienced displacement and safety factors, with the stress experienced being at a point below the yield strength or yield strength so that the body construction was declared safe against the static loading received, so that the test results this provides detailed insight into material strength, structural design, and possible improvements that can be made to reduce the risk of rider injury.

Combined design of dielectric material and layer structure of vanadium nitride/graphene composites for ultra-broadband microwave absorption

Combined design of dielectric material and layer structure of vanadium nitride/graphene composites for ultra-broadband microwave absorption

A 3D network-structured gel polymer electrolyte with soluble starch for enhanced quasi-solid-state lithium-sulfur batteries

The polysulfide shuttling effect and safety concerns associated with liquid electrolytes impede the commercialization of lithium-sulfur (Li-S) batteries. We report a novel gel polymer electrolyte (GPE) denoted as "PTPHS" prepared via facile ultraviolet polymerization of pentaerythritol tetrakis (3-mercaptopropionate) (PETT) and pentaerythritol tetraacrylate (PETEA) with poly (vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP) as the polymer matrix. Soluble starch (SST) is incorporated as an interacting filler to construct a 3D network structure with intermolecular hydrogen bonds. This unique architecture not only ensures high ionic conductivity and mechanical robustness but also effectively mitigates the polysulfide shuttling effect, thereby improving cycling stability. The PTPHS-based Li-S cell exhibits stable cycling over 150 cycles at 0.2 C with 87.6 % capacity retention. This strategy provides insights into material development and structural design of GPEs for high-performance quasi-solid-state Li-S batteries.

New insights on impact wear of polycrystalline diamond compact: Effect of interface state on kinetic response and damage behavior

The impact wear of polycrystalline diamond compact (PDC) cutters caused by the discontinuous cutting during the drilling process significantly affects the lifespan and efficiency of the drilling tools. Different PDC impact contact interface states are realized through the selection of impact mating materials. Understanding the effects of different interface states on the kinetic response, damage behavior and impact wear mechanism of PDC is significant in guiding the practical design of material structures with excellent impact wear resistance. Therefore, the kinetic response and damage behavior of PDC impact with different mating materials are investigated. The results show that the kinetic response and damage behavior of PDC are correlated with the mechanical properties of the mating material and physicochemical changes at the impact surface interface. Adhesion and filling resulting from strong covalent bonding and filling effects mitigate the interfacial stress and reduce the average impact force of SiC and Al2O3. Moreover, brittle fracture and filling effects increase the consumption of kinetic energy of SiO2, resulting in an energy absorption of up to 86 %. In addition, the strong covalent bonding effects exacerbated the damage to the PDC interfaces, leading to the internal fracture of diamond particles and detachment at grain boundaries. Furthermore, the filling effect formed plays a specific protective role for diamonds. However, it increases the energy absorption rate and reduces the mating material damage efficiency. In this work, the relationship between impact interface state and impact wear mechanism has been established by understanding the kinetic response, damage morphology, and structural evolution.

Dynamic deformation behavior and mechanical properties of porous titanium: Coupling effect of high temperature and high strain rate

Porous titanium exhibits excellent mechanical properties and clarifying its dynamic deformation behavior with the rate-temperature effect can offer the significant insights for the structural design of materials. This article delves into the coupling effect of rate and temperature, as well as the local deformation mechanisms of porous titanium subjected to high-temperature and high-strain-rate conditions (−823 K and −8000/s, respectively). A dynamic balance formula for rate-temperature competition has been introduced for application in high-temperature and high-strain-rate conditions. The local relative deformation observed at the end face exceeds 300% than other regions, while the degree of end surface densification reaches 61.5%.

Quantification of delamination resistance data of FRP composites and its limits

Quantitative delamination resistance data of fibre-reinforced polymer-matrix (FRP) composites for quasi-static or cyclic fatigue loads are determined under different loading modes and load rates, respectively. Such data find use, e.g., in FRP materials’ development, materials’ selection, assessment of durability, or structural design. Round robins during test development yielded repeatability and reproducibility (coefficients of variation) of roughly 10 to 25%. This scatter has several different sources. Intrinsic material variability amounts to a few percent at best, at least for advanced manufacturing processes. This intrinsic scatter is essential for material comparisons and structural design. Measurement resolution specified in standardised test procedures yields a maximum of 4–5% variability. Most of the remaining scatter comes from other, extrinsic sources. Test operator actions, e.g., choice of test set-up, manual data acquisition or data analysis can yield extrinsic scatter. Damage mechanisms during delamination initiation and propagation act on the micro- and meso-scale, typically a few micrometer to a few hundred micrometer in size, with corresponding time-scales estimated to between a few tens of nanoseconds and a few microseconds. Defect size-scales are hence several orders of magnitudes lower than test specimen and structural scales, respectively. Predictive capability of models using such test data for structures are, therefore, limited. Major issues are up-scaling from straight beam-like specimens to larger shell-like structures, possibly with complex shape and varying thickness as well as from unidirectional fibre orientation to multidirectional lay-ups.

Biomimetic heat-localized and solar absorption-enhanced hollow structural nanofibrous membrane for clean water production from saline water and dye wastewater

The rational design of material structures can be an effective approach to enhance the performance of solar-driven clean water production. In this study, a hollow structural nanofibrous membrane was developed by mimicking the hollow structure of polar bear hair using coaxial electrospinning. The shell layer consisted of carbon nanoparticles (C NPs) decorated CuO nanosheets (C@CuO), that exhibited photothermal conversion capacity. Meanwhile, the core layer containing hydrophilic polyvinylpyrrolidone (PVP) was eliminated to generate the hollow structure. The C NPs enhanced the membrane’s light absorption to increase thermal energy harvesting, while the CuO nanosheets improved the membrane’s wettability enhancing the water supply. Furthermore, the hollow structure limited air convection, prevented heat conduction, and minimized heat radiation, enabling heat localization to be achieved inside the membrane to suppress heat loss during evaporation. For 3.5 wt% saline water and actual dye wastewater, the C@CuO nanofibrous membrane achieved high evaporation rates of 1.36 kg·m−2·h−1 and 1.31 kg·m−2·h−1, respectively, under 1 sun illumination. Moreover, even after continuous 6-h evaporation tests, the evaporation rate of the C@CuO membrane remained virtually unchanged, highlighting its long-term stability with regard to salt resistance in real-world applications. Additionally, the remarkable flexibility of the C@CuO membrane offers convenience during operation and guarantees dimensional stability when it is subjected to external stresses. These discoveries should inspire subsequent research on developing delicate architectural materials and exploring their potential applications in various fields, including energy generation, clean water production, and thermal insulation.

Simulation-Directed Construction of Bamboo-Forest-Like Heat Conduction Networks to Enhance Silicon Rubber Composites' Heat Conduction Properties.

Highly vertically thermally conductive silicon rubber (SiR) composites are widely used as thermal interface materials (TIMs) for chip cooling. Herein, inspired by water transport and transpiration of Moso bamboo-forests extensively existing in south China, and guided by filler self-assembly simulation, bamboo-forest-like heat conduction networks, with bamboo-stems-like vertically aligned polydopamine-coated carbon fibers (VA-PCFs), and bamboo-leaves-like horizontally layered Al2O3(HL-Al2O3), are rationally designed and constructed. VA-PCF/HL-Al2O3/SiR composites demonstrated enhanced heat conduction properties, and their through-plane thermal conductivity and thermal diffusivity reached 6.47W(mK)-1 and 3.98mm2s-1 at 12vol% PCF and 4vol% Al2O3 loadings, which are 32% and 38% higher than those of VA-PCF (12vol%) /SiR composites, respectively. The heat conduction enhancement mechanisms of VA-PCF/HL-Al2O3 networks on their SiR composites are revealed by multiscale simulation: HL-Al2O3 bridges the separate VA-PCF heat flow channels, and transfers more heat to the matrix, thereby increasing the vertical heat flux in composites. Along with high volume resistivity, low compression modulus, and coefficient of thermal expansion, VA-PCF/HL-Al2O3/SiR composites demonstrate great application potential as TIMs, which is proven using multiphysics simulation. This work not only makes a meaningful attempt at simulation-driven biomimetic material structure design but also provides inspiration for the preparation of TIMs.