Finite Element Simulation Research Articles

Anion trapping-coupling strategy driven asymmetric nonflammable gel electrolyte for high performance sodium batteries

Gel polymer electrolytes, promising electrolyte candidates for advanced sodium metal batteries (SMBs), suffer from the great challenges of combustion risk and inferior interfacial stability caused by poor mechanical properties and low Na+ selectivity. Herein, we proposed a rational anion trapping-coupling strategy to build a mechanically robust asymmetric nonflammable composite gel electrolyte (AS-NFCGE) by introducing in-situ coupled boron nitride nanosheets (BNNs) on glass fiber matrix embedded with synchronous polymerized flame-retardant polymer. Theoretical calculations, finite-element simulations, and experimental tests prove that the high coupling BNNs with anion trapping effect constructed asymmetric structure can significantly accelerate selective Na+ migration kinetics, enhance mechanical properties of AS-NFCGE and endow a similar single-ion conducting behavior to homogenize ion-distribution at the anode side, thus improving interfacial stability and suppressing dendrite growth to achieve ultra-stable SMBs. Specifically, the AS-NFGE delivers high ionic conductivity and Na+ transference number (0.73) together with excellent flam-retardant. Consequently, the dendrite-free Na/Na symmetric cell exhibits considerable cycling life for over 3000 h at 0.1 mA cm−2 with low overvoltage. Applications of the AS-NFCGE in SMBs further demonstrate the excellent electrochemical performances, and no thermal runaway and no electrolyte leakage occur for pouch cells using AS-NFCGE. This strategy provides new insight into the development of safe and high-energy SMBs and the beyond.

An integrated computation framework for predicting mechanical performance of single-phase alloys manufactured using laser powder bed fusion: A case study of CoCrFeMnNi high-entropy alloy

Establishing a process-structure-property (PSP) relationship is crucial for understanding and optimizing the mechanical properties of components via laser powder bed fusion (L-PBF) additive manufacturing (AM). However, the parameters pertinent to the PSP relationship are encapsulated in a “black box” with a high dimension, resulting in relying on trial-and-error approaches to elucidate hidden associations becoming impracticable, while the acquisition of microscopic data proves financially burdensome. Thus this paper presents an integrated computation framework based on machine learning (ML) for predicting the tensile yield strengths and post-yield hardening rates of single-phase alloys fabricated through L-PBF, for efficient process optimization purposes. Research herein focuses on single-phase alloys to be built via L-PBF, taking CoCrFeMnNi high-entropy alloy as a study case, and provide an efficient integrated computation solution. The methodology proposed in this paper generates as-built microstructures associated with the varying L-PBF process parameters via cellular automata (CA). Subsequently, the mechanical responses of these microstructures are estimated by employing crystal plasticity finite element (CPFE) simulations. In addition, the approach raised in the paper leverages particle-level microstructure descriptors instead of average feature descriptors for the entire representative volume element (RVE) structure in an ML framework to predict the characteristics of the newly randomly growing grains. This research demonstrate the practicality and instructiveness of the methodology for modeling realistic grains. Then, trained ML model exhibits promising accuracy for the prediction of mechanical properties. This work showcases an integrated computation framework combining advanced materials science and ML techniques for enhancing understanding of the L-PBF process and offering valuable insights into process optimization for L-PBF-built diverse materials.

Experimental and Numerical Simulation of Reinforced Concrete-Filled Square GFRP Tubular Columns under Axial Compression

To investigate the axial compressive behavior of reinforced concrete-filled square glass-fiber-reinforced polymer(GFRP) tubular (RCFSGT) columns, 17 specimens were designed with variations in GFRP tube wall thickness, spiral reinforcement yield strength, and spiral reinforcement ratio. A detailed model was developed using the finite element software ABAQUS, enabling in-depth mechanistic analysis and expanded parameter studies. The results indicate that the failure types of the specimens are all manifested as GFRP square tube cracking, and the core concrete is subjected to crushing or shear failure. The inclusion of a reinforcement cage can significantly enhance the load-bearing capacity and ductility of the specimen. Furthermore, as the yield strength and reinforcement ratio of the spiral reinforcement increase, so does the load-bearing capacity of the specimen. The finite element simulation results align well with the experimental findings. As the wall thickness of the GFRP square tube increases from 2 mm to 6 mm, the load-bearing capacity improves by approximately 19.69%. With the yield strength of the spiral reinforcement rising from 200 MPa to 400 MPa, the specimen’s load-bearing capacity shows an increase of approximately 7.55%. However, as its yield strength continues to increase, there is minimal change in the load-bearing capacity. When the stirrup ratio of spiral reinforcement rises from 0.33% to 2.26%, the specimen’s load-bearing capacity experiences an increase of approximately 56.90%.

Mechanical Response and deformation mechanism of the utility tunnel crossing earth fissure

The structural safety of the utility tunnel is adversely affected when it passes through an area with earth fissures. Using the comprehensive tunnel project at the f7 earth fissure site in Xi'an as the engineering prototype, finite element simulation was employed to investigate the mechanical responses and deformation laws of the utility tunnel under different relative positions of earth fissures and deformation joints. Simultaneously, the deformation mechanism of a utility tunnel crossing an earth fissure was explored by using theoretical analysis. The results show that the influence of the earth fissure on the surface deformation of the hanging wall is greater than that of the footwall, and the main deformation is near the earth fissure. In addition, because the rigidity of the utility tunnel greatly exceeds that of the soil, the surface deformation at the earth fissure does not show a sudden change in form as dislocation generated by the hanging wall and footwall. Earth fissure movement mainly affects the stress change in the utility tunnel in the crossing ground fissure section. Moreover, the void area will be generated by the dislocation of the earth fissure near the earth fissure position at the bottom of the utility tunnel, which is not conducive to the stress of the utility tunnel. The research results contribute to optimizing the design of utility tunnel projects and enhancing the structural safety of tunnels. Additionally, they provide important reference points for the maintenance and management of comprehensive utility tunnels, enabling timely identification and resolution of the impacts of earth fissures on tunnel structures, thus ensuring the long-term stable operation of the tunnels.

A novel design method based onmulti–objective optimization for graded lattice structure by additive manufacturing

Purpose While performance demands in the natural world are varied, graded lattice structures reveal distinctive mechanical properties with tremendous engineering application potential. For biomechanical functions where mechanical qualities are required from supporting under external loading and permeability is crucial which affects bone tissue engineering, the geometric design in lattice structure for bone scaffolds in loading-bearing applications is necessary. However, when tweaking structural traits, these two factors frequently clash. For graded lattice structures, this study aims to develop a design-optimization strategy to attain improved attributes across different domains. Design/methodology/approach To handle diverse stress states, parametric modeling is used to produce strut-based lattice structures with spatially varied densities. The tailored initial gradients in lattice structure are subject to automatic property evaluation procedure that hinges on finite element method and computational fluid dynamics simulations. The geometric parameters of lattice structures with numerous objectives are then optimized using an iterative optimization process based on a non-dominated genetic algorithm. Findings The initial stress-based design of graded lattice structure with spatially variable densities is generated based on the stress conditions. The results from subsequent dual-objective optimization show a series of topologies with gradually improved trade-offs between mechanical properties and permeability. Originality/value In this study, a novel structural design-optimization methodology is proposed for mathematically optimizing strut-based graded lattice structures to achieve enhanced performance in multiple domains.

All-Textile Piezoelectric Nanogenerator Based on 3D Knitted Fabric Electrode for Wearable Applications.

Flexible, air permeable and elastic self-powered sensors for human motion monitoring and assisted medical rehabilitation have recently become a hot research topic. However, most current piezoelectric sensors can not account for many characteristics. Addressing this challenge, an all-textile piezoelectric sensor (ATPS) based on 3D structured knitted fabric electrodes is reported. The ATPS consists of a piezoelectric element polyvinylidene fluoride nanofiber membrane, flexible knitted fabric electrodes, and an elastic self-adhesive bandage. Based on the flexible and efficient knitting technology, the sensor has the advantages of low cost, flexibility, simple structure, and convenient large-area manufacturing. Experimental and finite element simulation results show that the knitting pattern of fabric electrodes can enhance the piezoelectric output of ATPS. The optimal ATPS has a high voltage response sensitivity of up to 0.68 V/kPa. The proposed ATPS responds to a wide range of input forces from 0.098 to 724 N in self-powered mode, verifying its feasibility as a tactile sensor for human motion detection and recognition (throat swallowing, wrist bending, elbow bending, knee bending, walking slowly, running fast) and as a pressure sensor (Morse code, digit recognition) and demonstrating its potential for motion tracking, medical rehabilitation, and human-computer interaction.

Evaluation of residual load-bearing capacity for corroded steel strands via MMM technique

The quantitative evaluation of the residual load-carrying capacity of corroded cables is critical to the safe service of bridge structures. In this study, the locally corroded steel strands with different corrosion degrees were obtained through electrochemical experiments and the metal magnetic memory (MMM) signals were collected by the TSC-9 M-12 tester. The tensile failure tests of corroded steel strands were conducted by the WAW-1000 tensile testing machine. The distribution laws of the normal component Hz signals for steel strands in different corrosion cases were detailed and a three-dimensional (3D) magnetic dipole model of corroded steel strands was developed considering the end effects. The linear relationships between the magnetic characteristic quantity Hn and the corrosion cross-section loss rate As were revealed and verified by the theoretical and finite element simulation results. Based on the above relationships, a quantitative linear relationship between the residual load-carrying capacity F and the corrosion cross-section loss rate As of the corroded steel strand was proposed. The relative errors of the residual load-carrying capacity F calculated by the proposed quantitative method were overall within 20%. This study provides a basis for evaluating the residual load-carrying capacity of corroded cables using the MMM technique.

Efficient Neutral H2O2 Electrosynthesis from Favorable Reaction Microenvironments via Porous Carbon Carrier Engineering

The efficient electrosynthesis of hydrogen peroxide (H2O2) via two‐electron oxygen reduction reaction (2e‐ ORR) in neutral media is undoubtedly a practical route, but the limited comprehension of electrocatalysts has hindered the system advancement. Herein, we present the design of model catalysts comprising mesoporous carbon spheres‐supported Pd nanoparticles for H2O2 electrosynthesis at near‐zero overpotential with approximately 95% selectivity in a neutral electrolyte. Impressively, the optimized Pd/MCS‐8 electrocatalyst in a flow cell device achieves an exceptional H2O2 yield of 15.77 mol gcatalyst‐1 h‐1, generating a neutral H2O2 solution with an accumulated concentration of 6.43 wt.%, a level sufficiently high for medical disinfection. Finite element simulation and experimental results suggest that mesoporous carbon carriers promote O2 enrichment and localized pH elevation, establishing a favorable microenvironment for 2e‐ ORR in neutral media. Density functional theory calculations reveal that the robust interaction between Pd nanoparticles and the carbon carriers optimized the adsorption of OOH* at the carbon edge, ensuring high active 2e‐ process. These findings offer new insights into carbon‐loaded electrocatalysts for efficient 2e‐ ORR in neutral media, emphasizing the role of carrier engineering in constructing favorable microenvironments and synergizing active sites.

A new model of thermo-mechanical actuation for twisted and coiled polymer muscles with initial curvature

The twisted and coiled polymer (TCP) artificial muscle is one type of novel soft actuator for mimicking natural skeletal muscle that can provide large linear and torsional actuation and energy density. Twisting and coiling are the pivotal steps in fabricating TCP muscles. The influence of twisting on the actuation response of TCP muscles has been extensively investigated recently. However, the influence of coiling remains unclear. Based on the finite strain theory, we establish a new thermo-mechanical actuation model for TCP muscles with initial curvature. The theoretical predictions based on the model align well with the finite element simulations, accurately capturing the actuation response of thermally-activated TCP muscles. It is revealed that twisting contributes positively to the actuation, while coiling has a passive effect. Geometrical parameters, such as the helix radius and helix angle, can effectively regulate the actuation performance of TCP muscles. Furthermore, an optimal bias angle is identified that maximizes both the recovery torque and the linear actuation. This study sheds light on the structural optimization design of TCP muscles.

Enhanced Energy Storage in PVDF-Based Nanocomposite Capacitors through (00l)-Oriented BaTiO3 Single-Crystal Platelets.

Flexible nanocomposite dielectrics with inorganic nanofillers exhibit great potential for energy storage devices in advanced microelectronics applications. However, high loading of inorganic nanofillers in the matrix results in an inhomogeneous electric field distribution, thereby hindering the improvement of the energy storage density (Ue) of the dielectrics. Herein, we proposed a strategy that utilized (00l)-oriented barium titanate (BT) single-crystal platelets to fabricate trilayered nanocomposite dielectrics for energy storage applications. The trilayered nanocomposites consisted of two high-permittivity layers of (Ta2O5, Al2O3) codoped TiO2 nanoparticles (Ta-Al@TiO2 nps) dispersed in a poly(vinylidene fluoride) (PVDF) matrix to facilitate large electric displacement and a middle layer of (00l)-oriented BT single-crystal platelets to provide high breakdown strength. Hence, the trilayered PVDF/Ta-Al@TiO2 nps/BT single-crystal platelet nanocomposite film attains an outstanding Ue of 16.9 J cm-3 at 370 kV mm-1, which is ∼625% higher than that of the single-layer PVDF/Ta-Al@TiO2 nps film. Finite element simulation further clarified that the successive inner layer of highly (00l)-oriented BT single-crystal platelets could effectively restrain the propagation of electrical treeing in trilayered nanocomposites. This research offers an effective approach for developing flexible dielectric capacitors with an excellent energy storage performance.

Analysing the shape memory behaviour of GnP-enhanced nanocomposites: A comparative study between experimental and finite element analysis

Abstract Shape memory polymers (SMPs) are capable of enduring significant deformations and returning to their original form upon activation by certain external stimuli. However, their restricted mechanical and thermal capabilities have limited their broader application in engineering fields. To address this, the integration of graphene nanoplatelets (GnPs) with SMPs has proven effective in enhancing their mechanical and thermal properties while maintaining inherent shape memory functions. The study evaluated shape memory nanocomposites (SMNCs) using dynamic mechanical, thermogravimetric, and static tensile, flexural, and shape memory tests, along with scanning electron microscopy to analyse tensile fractures. The results indicate that the optimal content of GnP is 0.6 wt%, resulting in excellent shape memory, thermal, and mechanical properties. Specifically, this composition demonstrates a shape recovery ratio of 94.02%, a storage modulus of 4580.07 MPa, a tensile strength of 61.42 MPa, and a flexural strength of 116.37 MPa. Additionally, the incorporation of GnPs into epoxy reduces recovery times by up to 52% at the 0.6 wt% concentration. While there is a slight decrease in the shape fixity ratio from 98.77% to 93.02%, the shape recoverability remains consistently high across all samples. Current finite element (FE) models often necessitate complex, problem-specific user subroutines, which can impede the straightforward application of research findings in real-world settings. To address this, the current study introduces an innovative finite element simulation method using the widely used ABAQUS software to model the thermomechanical behaviour of SMNCs, importantly incorporating the time-dependent viscoelastic behaviour of the material. The effectiveness of this new approach was tested by comparing experimental results from bending test of SMNCs cantilever beam with outcomes derived from FE simulations. The strong agreement between the experimental data and simulation results confirmed the precision and reliability of this novel technique.

Band flipping and bandgap closing in a photonic crystal ring and its applications

The size of the bandgap in a photonic crystal ring is typically intuitively considered to monotonically grow as the modulation amplitude of the grating increases, causing increasingly large frequency splittings between the "dielectric" and "air" bands. In contrast, here we report that as the modulation amplitude in a photonic crystal ring increases, the bandgap does not simply increase monotonically. Instead, after the initial increase, the bandgap closes and then reopens again with the two bands flipped in energy. The air and dielectric band edges are degenerate at the bandgap closing point. We demonstrate this behavior experimentally in silicon nitride photonic crystal microrings, where we show that the bandgap is closed to within the linewidth of the optical cavity mode, whose intrinsic quality factor remains unperturbed with a value ≈ 1×106. Moreover, through finite-element simulations, we show that such bandgap closing and band flipping phenomena exist in a variety of photonic crystal rings with varying unit cell geometries and cladding layers. At the bandgap closing point, the two standing wave modes with a degenerate frequency are particularly promising for single-frequency lasing applications. Along this line, we propose a compact self-injection locking scheme that integrates many core functionalities in one photonic crystal ring. Additionally, the single-frequency lasing might be applicable to distributed-feedback (DFB) lasers to increase their manufacturing yield.

Linear and nonlinear axial behaviour of internal replacement pipe systems for pipeline rehabilitation

Internal replacement pipe (IRP) is an innovative trenchless technology for the rehabilitation of legacy steel and cast-iron pipelines. This advanced IRP system must be properly designed so that it can safely and effectively restore the service of damaged pipelines. This paper studies the axial behaviour of IRP systems for repairing pipelines with circumferential host-pipe discontinuities under seasonal and extreme levels of temperature change. Analytical solutions along with a total of 270 linear and nonlinear finite element (FE) simulations, validated against experimental results and available closed-form solutions, were used for a parametric study on the effects of geometrical and material properties on axial stresses and deformations of IRP systems subjected to temperature change. Effects of the internal pressure, material and geometric nonlinearities, and different modes of IRP-host pipe unbonding were also investigated. An analytical model was developed for the prediction of temperature change induced loading and response of the IRP system. Using the results obtained from a comprehensive FE-based parametric study, three modification factors were extracted for the application to the developed analytical model in order to accurately predict the maximum axial stress of IRP and the opening of a circumferential host-pipe discontinuity subjected to various levels of temperature change.

Enhancing thermal-mechanical performance of micron Ag/ZrW2O8 nanorod die-attach paste with low thermal expansion

Negative thermal expansion not only challenges the traditional lattice concept, but also provides new opportunities for regulating the thermal expansion coefficient and addressing the increasing reliability demands in power device packaging. In this study, ZrW2O8 nanorods were firstly introduced into the micron Ag paste via a facile low-temperature (≤300 ℃) low-pressure (<10 MPa) sintering. The pinning and negative thermal expansion mechanisms contributed by the homogeneously dispersed ZrW2O8 nanorods significantly mitigate the thermal expansion mismatch and suppress the microstructure deterioration in SiC power module, which was also verified by finite element (FE) simulation. The Ag@2%ZrW2O8 (2% of the total weight of Ag) specimen possessed outstanding long-term reliability with a die-shear strength of 29.63 MPa after 1000 thermal shock cycles from −50–250 ℃. The novel findings can be inspiring on interconnected material optimization and selection in electric packaging application as well as reliability evaluation in the service condition.

A Conceptual Framework to Understand the Self-Assembly of Chemically Active Colloids.

Colloids that generate chemicals, or "chemically active colloids", can interact with their neighbors and generate patterns via forces arising from such chemical gradients. Examples of such assemblies of chemically active colloids are abundant in the literature, but a unified theoretical framework is needed to rationalize the scattered results. Combining experiments, theory, Brownian dynamics, and finite element simulations, we present here a conceptual framework for understanding how immotile, yet chemically active, colloids assemble. This framework is based on the principle of ionic diffusiophoresis and diffusioosmosis and predicts that a chemically active colloid interacts with its neighbors through short- and long-range interactions that can be either repulsive or attractive, depending on the relative diffusivity of the released cations and anions, and the relative zeta potential of a colloidal particle and the planar surface on which it resides. As a result, 4 types of pairwise interactions arise, leading to 4 different types of colloidal assemblies with distinct patterns. Using short-range attraction and long-range attraction (SALR) systems as an example, we show quantitative agreement between the framework and experiments. The framework is then applied to rationalize a wide range of patterns assembled from chemically active colloids in the literature exhibiting other types of pairwise interactions. In addition, the framework can predict what the assembly looks like with minimal experimental information and help infer ionic diffusivity and zeta potential values in systems where these values are inaccessible. Our results represent a solid step toward building a complete theory for understanding and controlling chemically active colloids, from the molecular level to their mesoscopic superstructures and ultimately to the macroscopic properties of the assembled materials.

Determining the Drucker-Prager Cap model constants using experimental, numerical and optimization for compacted Mg powders at different strain rates

This article investigates an inverse approach to determine the coefficients of the Drucker-Prager model for magnesium powder. The approach involves conducting finite element simulations of the powder compression process within LS-DYNA software, employing the Drucker-Prager material model. The goal is to minimize the disparity between force-displacement outcomes derived from simulations and experimental data using a surrogate optimization method. Experimental data were obtained through a uniaxial compression test and served as a basis for adjusting the Cap model coefficients. A random selection of coefficients was made using the Latin cube method and simulations were performed based on the initial coefficients. The optimization was then performed using the particle swarm algorithm over 20 iterations. The optimized coefficients were validated against experimental data, demonstrating close agreement. By utilizing the extracted coefficients, the relative density of the samples was calculated at three different compaction speeds, i.e., 15.5 m s−1 (using a Hopkinson bar), 8 m s−1 (using a drop weight), and 1 mm min−1 (using an Instron machine). The analysis revealed the highest relative density and stress in the densified sample via the Hopkinson bar method, reaching 99.83% and 1.1 GPa, respectively.

The Effects of Induction Plasma Spheroidization on the Properties of Yttrium-Stabilized Zirconia Powders and the Performance of Corresponding Thermal Barrier Coatings for Gas Turbine Engine Applications

To modify the structure of thermal barrier coatings and improve their high-temperature resistance, induction plasma spheroidization (IPS) technology was applied to regulate the structure of YSZ powders in this study. The surface morphology, particle size distribution, phase composition, and internal microstructure of the conventional agglomerated and spheroidized powders were characterized using scanning electron microscopy and focused ion beam analysis methods. The results showed that the microstructure of the powders presented uneven evolution in the induction plasma stream. Due to the existence of the temperature gradient along the radial direction of the powders, the IPS powders consisted of outer dense shells and internal porous cores. The mechanical property of such shell–core structure was analyzed by using the finite elemental simulation method. In addition, coatings were prepared using the IPS powders and the agglomerated powders. The IPS coating showed improved water-cooling thermal cycling resistance compared to the conventional coating.

Characterisation and modelling of anisotropic hardening behaviour of cubic and hexagonal close packed polycrystalline metals

ABSTRACT In this study, anisotropic non-proportional hardening behaviour of the sheet metals with different crystalline structures is investigated. The investigated materials particularly exhibit the Bauschinger effect and complex transient hardening behaviour during loading path change. Furthermore, the finite element simulations are carried out to evaluate the performance of the distortional and multi-surface-kinematic hardening models in flow stress prediction under loading path change. Both models can well reproduce the measured anisotropic hardening, but the distortional hardening concept shows better predictive capability for flow stresses. The improved accuracy of the flow stress prediction with the distortional hardening model compared to the kinematic hardening is attributed to its flexibility in distortion of the yield surface following microstructure deviator independent on the initial yield surface. In contrast, the initial size of the yield surface in the kinematic hardening significantly affects the determination of the re-yielding stress at load reversal.

Theoretical and Experimental Investigations of Identifying Bridge Damage Using Instantaneous Amplitude Squared Extracted from Vibration Responses of a Two-Axle Passing Vehicle

Identifying bridge damage using a movable test vehicle is highly regarded for its mobility, cost-effectiveness, and broad monitoring coverage. Previous studies have shown that the residual contact-point (CP) response between connected vehicles is free of the impact of vehicle self-vibrations and road roughness, making it particularly suitable for the indirect extraction of bridge modal properties. However, most experimental campaigns regarding contact-point (CP) responses focus on a single-axle testing vehicle within a non-moving state. This study aims to theoretically and experimentally identify bridge damage using the instantaneous amplitude squared (IAS) extracted from the residual CP response of a two-axle passing vehicle. First, the closed-form solution of the residual CP acceleration was derived for a two-axle vehicle interacting with a simply supported beam. The IAS index was constructed from the driving frequency of the residual CP acceleration. Then, numerical investigations using finite element simulation were conducted to validate using the IAS index for indirect bridge damage identification. The application scope of the approach under various vehicle speeds and road roughness grades was examined. Finally, a laboratory vehicle–bridge interaction system was tested to validate the approach. Numerical studies demonstrated that bridge damage could be directly determined by observing the IAS abnormalities, which were baseline-free. The IAS from the residual CP response outperformed the IAS from CP responses in identifying bridge damage. However, it was better to use the IAS when the vehicle speed was no greater than 2 m/s and the grade of the road surface roughness was not high. Laboratory tests showed that it was possible to identify bridge damage using the IAS extracted from the residual CP acceleration under perfect road surfaces. However, it fell short under rough road surfaces. Hence, further experiments are required to fully examine the capacity of the IAS for bridge damage identification in practical applications.

Analysis and design of wireless power transfer system with anti-misalignment constant voltage output characteristics

Analysis and design of wireless power transfer system with anti-misalignment constant voltage output characteristics