Material Failure Research Articles

STUDY ON THE INFLUENCE OF 1 AND 15μm PITCH VALUES ON THE APPARENT NANOMECHANICAL PROPERTIES OF LASER POWDER BED FUSION-PRODUCED CuCrZr ALLOY

Material deformation due to nanoindentation is well known. However, the deformation of a material, indentation cavity, and piled-up region drastically increases and nanohardness significantly decreases if the nanoindentation is performed in such a way that the deformation of one nanoindentation affects the others. This situation arises in various materials when they are subjected to tribological application such as pantograph assembly in electric trains and contact between the electrical power supply plug and pins. This situation has been addressed in this study and the quantitative reduction in nanohardness has been evaluated in detail. In this work, the nanoindentation was performed on the laser powder bed fusion (LPBF) CuCrZr alloy specimen under a load condition of 4500[Formula: see text][Formula: see text]N. This test was conducted at 100 points with an array of [Formula: see text] at a 1[Formula: see text][Formula: see text]m pitch value. Two significant findings were identified in this work. First, the indentation impression was smaller and the corresponding nanohardness and contact stiffness values were higher in the first column of 10 nanoindentations and the first row of 10 nanoindentations. The remaining 80 nanoindentations displayed contrasting behavior compared to the initial 20 nanoindentations due to the prior deformation of nearer regions. Nanohardness value decreased parabolically from the low deformation to the high deformation region. This finding was validated by increasing the pitch to 15[Formula: see text][Formula: see text]m under the 4500[Formula: see text][Formula: see text]N load conditions. The piled-up region around the impression of indentation changed from a semi-circular shape at a 15[Formula: see text][Formula: see text]m pitch value to a cone shape at a 1[Formula: see text][Formula: see text]m pitch value. These findings will be beneficial for industries during the design of materials and will help reduce material failures resulting from tribological activities.

Enhancing the Mechanical Properties of Injectable Nanocomposite Hydrogels by Adding Boronic Acid/Boronate Ester Dynamic Bonds at the Nanoparticle-Polymer Interface.

Incorporating nanoparticles into injectable hydrogels is a well-known technique for improving the mechanical properties of these materials. However, significant differences in the mechanical properties of the polymer matrix and the nanoparticles can result in localized stress concentrations at the polymer-nanoparticle interface. This situation can lead to problems such as particle-matrix debonding, void formation, and material failure. This work introduces boronic acid/boronate ester dynamic covalent bonds (DCBs) as energy dissipation sites to mitigate stress concentrations at the polymer-nanoparticle interface. Once boronic acid groups were immobilized on the surface of SiO2 nanoparticles (SiO2-BA) and incorporated into an alginate matrix, the nanocomposite hydrogels exhibited enhanced viscoelastic properties. Compared to unmodified SiO2 nanoparticles, introducing SiO2 nanoparticles with boronic acid on their surface improved the structural integrity and stability of the hydrogel. In addition, nanoparticle-reinforced hydrogels showed increased stiffness and deformation resistance compared to controls. These properties were dependent on nanoparticle concentration. Injectability tests showed shear-thinning behavior for the modified hydrogels with injection force within clinically acceptable ranges and superior recovery.

Cavitation damage in rubber-like silicone adhesives

In this work, the failure of rubber-like materials by cavitation is investigated. Under local triaxial loading states, as they can occur in confined geometries of adhesive bonds, the instantaneous formation of voids can be observed. Analytical results of cavitation in a commercial silicone adhesive are provided. The results show that cavitation voids can be distinguished from manufacturing voids by the inner surface of the void. The surface of the cavitation void is rugged and shows a complex fracture pattern. Pancake experiments have been conducted for different ratios of radius and thickness. To assess the fracture process of cavitation onset one macroscopic and two asymptotic solutions of the energy release rate of cavitation voids are proposed. The solutions are compared and their limitations for the analysis of cavitation onset are discussed.

Inflammation-responsive PCL/gelatin microfiber scaffold with sustained nitric oxide generation and heparin release for blood-contacting implants

Delayed endothelialization, the excessive proliferation of smooth muscle cells (SMCs), and persistent inflammation are the main reasons for the implantation failure of blood-contacting materials. To overcome this problem, an inflammation-responsive, core-shell structured microfiber scaffold is developed using polycaprolactone (PCL), selenocystamine-modified gelatin (Gel-Se), L-ascorbyl 6-palmitate (AP), and dexamethasone as the fiber shell, with poly (l-lysine) (PLL) and heparin incorporated in the fiber core. Superhydrophilic microfiber scaffolds exhibit antifouling properties that inhibit protein adsorption and blood cell adhesion, thereby effectively mitigating the risk of acute thrombosis. The continuous release of heparin and sustained generation of nitric oxide (NO) through the catalytic decomposition of S-nitrosothiols by selenocystamine lead to a biomimetic endothelial function for the enhancement of blood compatibility. The inflammation-responsive compound AP can detoxify excess reactive oxygen species (ROS) while controlling the release of dexamethasone to reduce chronic inflammation. We demonstrate the ability of microfiber scaffolds to reduce thrombotic and inflammatory complications, inhibit SMC proliferation, and promote rapid endothelialization both in vitro and ex vivo. Hence, microfiber scaffolds are robust and promising for blood-contacting implants with enhanced antithrombogenicity and anti-inflammatory capabilities.

Study on the bending mechanical properties of composite tube and metal joint bonding structure

Abstract The study of the mechanical properties of composite adhesively bonded joints is a very important issue, which directly affects the safety and reliability of the structure. This article studies the bending performance of carbon fiber composite tubes and metal joint bonding structures, as well as obtains the structural bearing capacity, influencing factors, and structural failure modes. Through mechanical analysis and static bending load tests, it is shown that the failure model of composite tube adhesively bonded metal joints under bending load is manifested as the first layer peeling or interlayer failure of the composite material in the bonding area between the tube and the joint, leading to local crushing at the end of the tube. There is no gap between the tube and the joint, which has little effect on the bending bearing capacity. The thickness gradient treatment at the end of the joint does not help improve the bending bearing capacity. The adhesive layer is at a 90 ° angle, which makes it easy for the first layer to peel off; it should be avoided. Other angle layers have little impact on load-bearing capacity. The longer the bonding length is, the stronger the bending capacity is. The adhesive J133 or 420 has a similar load-bearing. Wrapping a carbon fiber unidirectional layer around the ends of tubes and joints is helpful in improving their bending load-bearing capacity.

Being thin-skinned can still reduce damage from dynamic puncture.

The integumentary system in animals serves as an important line of defence against physiological and mechanical external forces. Over time, integuments have evolved layered structures (scales, cuticle and skin) with high toughness and strength to resist damage and prevent wound expansion. While previous studies have examined their defensive performance under low-rate conditions, the failure response and damage resistance of these thin layers under dynamic biological puncture remain underexplored. Here, we utilize a novel experimental framework to investigate the mechanics of dynamic puncture in both bilayer structures of synthetic tissue-mimicking composite materials and natural skin tissues. Our findings reveal the remarkable efficiency of a thin outer skin layer in reducing the overall extent of dynamic puncture damage. This enhanced damage resistance is governed by interlayer properties through puncture energetics and diminishes in strength at higher puncture rates due to rate-dependent effects in silicone tissue simulants. In addition, natural skin tissues exhibit unique material properties and failure behaviours, leading to superior damage reduction capability compared with synthetic counterparts. These findings contribute to a deeper understanding of the inherent biomechanical complexity of biological puncture systems with layered composite material structures. They lay the groundwork for future comparative studies and bio-inspired applications.

Microstructure evolution and fracture characteristics of GH4079 superalloy during high-temperature tensile process

An investigation of the thermal deformation characteristics and fracture mechanisms of the GH4079 superalloy was conducted through a series of hot tensile experiments conducted across a range of strain rates (from 0.01 s−1 to 1 s−1) and temperatures (from 970 °C to 1160 °C). The impact of MC carbides on the thermal deformation characteristics and dynamic recrystallization (DRX) of GH4079 superalloys, which are known for their challenging deformability, was analyzed to provide insights into enhancing the thermal workability of these formidable superalloys. The results suggest that DRX consistently preferentially occurs near MC carbides. The MC carbide plays a nucleation role in the particle-induced dynamic recrystallization mechanism, as determined via EBSD analysis. In addition, the primary grain boundary is the preferred nucleation site for DRX initiation. The promotion of DRX within the GH4079 alloy is considerably facilitated by the increased stored energy and nucleation site density resulting from the larger and more numerous carbides present at the grain boundaries. Moreover, the presence of carbides leads to uncoordinated deformation of the alloy during tensile deformation, which is also the induction factor of alloy cracking. With increasing strain rates and temperatures, the window of control over the hot deformation structure of the alloy diminishes. During the high-temperature deformation process of the GH4079 alloy, it is necessary to control the temperature within the range of approximately 1120 °C–1140 °C and the strain rate within the range of 0.1 s−1 to 1 s−1 to obtain a fine and uniform grain structure, delay material failure, and thus enhance the thermal processing performance of the material.

Design of tri-phase lamellar architectures for enhanced ductility in ultra-strong steel

Achieving exceptional ductility in ultra-high strength steels has long been a formidable challenge, particularly when the yield strength reaches 2.0 GPa. In this study, we have designed an innovative tri-phase lamellar microstructure in medium Mn steel that successfully achieves both an ultrahigh yield strength of approximately 2.0 GPa and an impressive uniform elongation ranging from 22.5 % to 24.5 %. The ultra-high yield strength of this steel is primarily due to the ultrafine lamellar grain with high-density dislocations and HDI strengthening resulting from meticulously designed tri-phase lamellae. The remarkable ductility is attributed to the synergistic action of multiple plasticity mechanisms. The inherently excellent plasticity of the lamellar ferrite, in coordination with the lamellar martensite, generates significant HDI hardening, thereby suppressing the onset of necking in the early stages of deformation. During the mid-stage of deformation, high strain activates the transformation-induced plasticity effect in the highly stable austenite, which remains stable due to substantial HDI hardening and effectively mitigates strain localization. In the later stages of deformation, delamination cracking relieves stress accumulation at the interfaces, delaying material failure. These mechanisms elevate yield strength and uniform elongation product to 47.3 GPa·%, showcasing the tri-phase lamellar structure’s potential for ultrahigh-strength, high-ductility steels.

A peridynamic-based reconstruction and analysis method for short-fiber reinforced composites

Abstract As the complex microstructure, predicting the effective elastic properties and damage mechanisms of Short-Fiber Reinforced Composites (SFRC) continues to pose a challenge. This study presents a new reconstruction and analysis method based on PeriDynamics (PD) for SFRC. The reconstruction of the surface profiles of short-fibers obtained from Micro-CT (Micro-Computed Tomography) scanning resulted in a PD computational model that accurately reflects the actual microstructure of SFRC. The results predicted the effective elastic modulus of SFRC while fiber volume fraction and distribution have impact. Micro-cracks emerge at stress concentration regions near the fiber-matrix-fiber interfaces between two adjacent fibers, and with increasing load, these cracks gradually propagate, interact, and merge with each other. Eventually, major cracks form, leading to material failure.

The bending of 3D-printed bio-inspired sandwich panels with wavy cylinder cores

Beetle Elytron Plates (BEPs) represent a new class of biomimetic sandwich cores with excellent mechanical properties inspired by the microstructure of the beetle elytra. The cores have a hexagonal centre-symmetric configuration with through-thickness cylinders in the unit cell. In this work, we describe the behaviour of sandwich panels with novel BEP core configurations possessing wavy cylinders under four-point bending tests. Full-scale simulations are also carried out to validate the experimental data. The results show that all the sandwich panels produced with face skins adhesively bonded have material failure earlier than the adhesive bond failure. BEPs with wavy cylinders have larger peak loads compared to those with straight cylinders, and all BEPs show higher peak loads than those of sandwich panels with classical hexagonal honeycombs. Additionally, all the BEPs exhibit an enhanced ductility compared to honeycomb sandwich panels.

Precise identification of delamination defect based on optimized deep learning method to understand mechanical property reduction

Ceramic matrix composites are advanced thermal structural materials used in aerospace and other fields due to their excellent performance. However, the common delamination defects in the interior can easily lead to material failure, posing significant threats to component reliability. Addressing this issue requires the development of precise and intelligent methodologies for the rapid identification of delamination defects and the evaluation of their impact on mechanical properties. In this study, delamination defects were intentionally introduced into SiCf/SiC composites to facilitate intelligent identification and quantitative analysis. We propose a novel network combining Mamba and Convolutional Neural Network, which surpasses existing models in defect segmentation by precisely capturing both global and local information, while optimizing computational efficiency and memory usage. Mechanical tests reveal that variations in delamination defects lead to an initial reduction followed by an increase in both tensile and compressive strengths. The minimum tensile and compressive strengths are 69.30% and 74.30% of those in non-defective control samples, respectively. Tensile strength is more sensitive to defect volume, as the reduced crack propagation path facilitates premature tensile fracture of the fibers, whereas compressive strength is more affected by defect depth due to compressive instability and stress concentration. This strategy provides a novel avenue for the intelligent identification and risk assessment of delamination defects in ceramic matrix composites.

Models and criteria of destruction of composite materials at the stage of macrocrack initiation

The analysis was carried out and the limits of the use of modern damage models and criteria for the failure of composite materials (CM) at the stage of macrocrack initiation were established. The classification of CM and the main hypotheses and assumptions used in the development of the condition level are described. The main stage of the life cycle of a CM product is considered - the stage of nucleation and accumulation of scattered fractures at the micro and meso levels. The main principles of continuum damage mechanics, thermodynamics of irreversible processes and mechanics of a solid deformed body are used. The main mechanisms of microfailure of reinforced CM are described. It is shown that for them it is necessary to consider a set of phenomenological parameters that could assess the kinetics of the accumulation of diffused failures in the matrix, reinforcing fibers and the delamination between them. These complex processes in reinforced CMs require phenomenological modeling of damage in the form of tensor quantities with certain assumptions. Thus, the "mixture" hypothesis was widely used. It is shown that each component of the damage parameter is more expedient to determine from the hypothesis of the equivalence of specific energies. The method of conducting basic experiments to specify the regularities of damage accumulation in CM is detailed. A modified CM stiffness tensor is established, taking into account the degradation of the mechanical properties of the CM, regardless of the thermo-force parameters of the operating load. An analysis of modern criteria for the destruction of reinforced CMs and the limits of their use was carried out. The main directions of solving the problem of estimating the limit state of CM and the load-bearing elements made from them are shown.

Influence of TiC particle size on microstructural evolution and fracture mechanism of TiC/Al-Cu composites

Using scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and molecular dynamics simulations, this work investigated the microstructure, texture evolution, strengthening mechanisms, and fracture progression of TiC/Al-Cu composites with various particle sizes following hot extrusion and heat treatment. TiC particles significantly refine grain sizes, shifting the dominant coincidence site lattice (CSL) boundaries from Σ5 to Σ3. The addition of TiC particles alters the preferred grain orientation from (111)/ED to (001)/ED, and modifies the type and intensity of the texture. The primary strengthening mechanisms attributed to TiC include grain boundary strengthening, dislocation strengthening, Orowan strengthening, and load transfer strengthening. However, the strong tendency of smaller TiC particles to agglomerate substantially diminishes these strengthening effects; thus, under a TiC addition of 0.5 wt%, larger TiC particles exhibit better mechanical properties. Fractographic analysis and molecular dynamics simulations revealed that microcracks originate from dissociation at the interfaces between the TiC agglomerates and the Al matrix. The subsequent propagation, expansion, and interconnection of multiple crack initiation sites lead to the formation of macroscopic cracks that result in material failure.

Failure analysis and optimization design of CFRP automotive seat back under multiple conditions

This study explores the adoption of carbon fiber reinforced plastic (CFRP) in automotive seat backrests, aiming to improve compliance with regulatory standards and enhance performance. By replacing conventional materials with CFRP, and employing mechanical performance tests alongside the principle of equal stiffness, the study tackles material failure issues. A novel multi-criteria decision-making method, coupled with an optimal Latin hypercube experimental design, is used to optimize the layup sequence. The optimized design not only meets regulatory requirements but also significantly enhances driver and passenger safety and comfort during collisions.

Spectroscopic Study of Strain, Oxidation, and Formation of Few-Layer Graphene at Steel Surfaces Tribologically Tested against MoS2 Films.

MoS2 not only has unique optoelectronic properties realizing photonic and semiconductor applications but also serves as a promising solid lubricant in tribological three-body contacts due to its advantageous friction and wear behavior. Its functionality is defined by elementary processes including strain, oxidation processes, and material mixing. However, these mechanisms were not elucidated for MoS2 having transferred from the MoS2 film synthesized at the main body to a steel counter body during tribological ball-on-disk tests. Using spatially and spectrally high-resolved Raman spectroscopy, we study the compressive and tensile strain within the MoS2 transfer material and analyze the oxidation of molybdenum, sulfur, and iron. In addition, we elaborate on the impact of transition metals modifying the MoS2 films on the strain distribution and oxidation processes. Decreasing intensities of the MoS2 Raman lines are accompanied with enhanced intensities of sulphur and molybdenum oxide Raman signatures which are particularly agglomerated at the edges of the tribological track. The formation of tribochemical oxides, including Mo4O11 in the Magnéli-phase, depends weakly on the type of modifying element, and an oxidation of a modification element itself is not detected. We also identified a tribologically induced formation of disordered few-layer graphene at counter-body surface areas which experienced weak thermo-mechanical tribological load. Our results characterize structural and chemical features of the MoS2 transfer material, thus predicting material failure at the microscopic level.

Degradation induced by charge relaxation in silicone gels under the ultra‐fast pulsed electric field

AbstractThe insulating properties of silicone gel used for silicon carbide‐insulated gate bipolar transistors encapsulation may deteriorate seriously under ultra‐fast pulsed electric fields. The essence of insulation degradation lies in the deterioration of materials caused by dynamic phenomena at microscopic scale, such as charge trapping and detrapping. Different from the steady‐state operating condition, insulating materials exhibit a sharp decrease in their insulating properties when subjected to a rapidly changing electric field. To investigate the insulation failure of silicone gel materials under an ultra‐fast pulsed electric field, Marcus hopping mechanism for charge response is proposed. By calculating the relaxation time with different defects, we characterise the degradation of the materials. According to the force analysis of space charge, the authors establish a relationship between insulation failures and charge relaxation time. Combined with the experimental results on electrical treeing in silicone gel, the feasibility of the theory is verified. The experimental phenomenon can be well explained, that is, the initial voltage of the electrical trees decreased sharply with shortening the edge time of the pulsed electric field, especially on the nanosecond time scale.

Theoretical Review of Weight Functions for Rigid Line Inclusions: Implications for Stress Singularities and Crack Propagation

A comprehensive theoretical analysis of weight functions for rigid line inclusions in elastic materials is presented. Classical fracture mechanics approaches were extended to accurately predict stress intensity factors (SIFs) at the tips of these inclusions, which are crucial for understanding material failure. The analysis covered both static and dynamic loading conditions, including transient Mode-III problems. Weight functions for various deformation modes were derived, and the impact of rigid line inclusions on stress singularities and crack propagation was explored. These insights are valuable for the design and analysis of composite structures and materials subjected to dynamic loading.

Research on Rock Energy Constitutive Model Based on Functional Principle

The essence of rock fracture can be broadly categorized into four processes: energy input, energy accumulation, energy dissipation, and energy release. From the perspective of energy consumption, the failure of rock materials must be accompanied by energy dissipation. Dissipated energy serves as the internal driving force behind rock damage and progressive failure. Given that the process of rock loading and deformation involves energy accumulation and dissipation, the rock constitutive model theory is expanded by incorporating energy principles. By introducing the dynamic energy correction coefficient, according to the law of the conservation of energy, the total energy exerted by external loads on rocks is equal to the energy dissipated through the dynamic energy inside the rocks. A new type of energy constitutive model is established through the functional principle and momentum principle. To validate the model’s accuracy, a triaxial compression test was conducted on sandstone to examine the stress–strain behavior of the rock during the failure process. A sensitivity analysis of the parameters introduced into the model was conducted by comparing the model results, which helped to clarify the innate laws of significance of these parameters. The results indicated that the energy model more accurately captures the non-linear mechanical behavior of sandstone under high-stress loading conditions. The model curve fits the test data to a high degree. The fitting curve was basically consistent with the changing trend of the test curve, and the correlation coefficients were all above 0.90. Compared with other models, the model based on the energy principle not only accurately reflects the rock’s stress–strain curve, but also reflects the energy change law of rock. This has reference value for the safety analysis of rock mass engineering under loading conditions and aids in the development of anchoring and support schemes. The research results can fill in the blanks that exist in the energy method in terms of rock deformation and failure and provide a theoretical basis for deep rock engineering. Moreover, this research can further improve and extend the rock mechanics research system based on energy.

Lifetime evaluation and material failure analysis of a PEMFC prepared using commercial materials

ABSTRACT Hydrogen fuel cells are vital for green energy to replace traditional energy. However, their lifetime is an important factor limiting their development. In this study, commercial materials were used to prepare proton exchange membrane fuel cells (PEMFCs), and pure oxygen was used as the cathode gas to accelerate their lifetime evaluation. The components of the membrane electrode assembly were characterized, and significant thinning was observed in the local proton exchange membrane (PEM). Therefore, the uniformity of the internal conditions of the fuel cell is the key to ensure a long lifetime. The hydrophilicity of the gas diffusion layers increased as the carbon disorder increased via the adsorption of hydrophilic chain segments produced by PEM degradation. The growth of platinum particles in the catalyst layer reduced the electrochemical active area of the catalyst, but the reduction rate slowed and then stabilized. This study of the lifetime of PEMFCs and changing properties of commercial materials clarifies the existing problems of fuel cells and contributes to the development of long-life fuel cells.

Wind-induced collapse mode and mechanism of super-large hyperbolic steel reticulated shell cooling tower with stiffening rings

With advancement of dry-air cooling technology, it has become feasible to use steel reticulated shell structures in design and construction of industrial cooling towers. Steel reticulated shell cooling towers (SRSCTs) with light weight, high strength, and rapid construction have development potential. Wind-induced collapse accidents in cooling towers frequently occur, characterized by pronounced nonlinear behavior involving significant deformation and material failure. Nevertheless, current stability and collapse analyses of cooling towers based on linear theory and elastic deformation are inadequate and unsafe. Thus, the wind-resistant stability of SRSCTs must be evaluated considering their inherent high flexibility and low damping levels. Considering a 220 m high hyperbolic SRSCT as a case study, a wind-induced collapse FEM simulation and analysis were performed. The average and fluctuating wind loads were measured in a reduced-scale model during wind tunnel tests and used as the time-variant wind pressure in a structural finite-element model. The dynamic performance and buckling collapse analyses of the cooling tower were conducted considering geometric and material nonlinearities. The entire wind-induced failure process of the SRSCT in extreme winds was systematically investigated. The weaknesses in the structural stiffness and the failure process were quantified, with five failure stages and four failure modes. The failure stages included linear elasticity, local member failure, local regional failure, overall structural failure, and collapse. The failure modes included circumferential plastic buckling zone failure, windward buckling failure of the shell, crosswind failure of the stiffening ring (hinged curved-beam mechanism), and windward failure of the stiffening ring (triangular arch-like mechanism). This study confirms that development of plastic buckling zones and formation of plastic hinges, considering geometric and material nonlinearity, are the dominant factor in wind-induced failure and collapse of SRSCTs.