Homogeneous Mechanical Properties Research Articles

Effect of crystallographic texture and grain orientation on tribological properties of WAAM deposited IN625 alloy in weaving deposition strategy

Understanding the variation in the local microstructure and texture of the as-built fabricated by wire arc additive manufacturing (WAAM) is highly challenging. They affect the mechanical and tribological properties of the builds. The deposition patterns and the process parameters are key factors that determine the microstructures and hence other properties. In the present study, builds of Inconel 625 alloy have been manufactured through WAAM by using a weaving pattern. The microstructure and their texture at the different locations of the deposited build have been investigated through electron backscattered diffraction (EBSD) and optical microscopy. The detailed evolution mechanisms of the micro-structure of the build have been studied followed by the quantitative analysis of the grain size, misorientation angles, fraction of recrystallized and deformed grains, and textures. Later the effect of texture components on the hardness, elastic modulus, and coefficient of friction (COF) of the build has been studied by using nano-indetation and nano-scratch tests. The grain size was found to be 33 μm, 110 μm, and 66 μm at the bottom, middle, and top, respectively. The top region was dominated by Cube {001}<uvw>, Goss {011}<100>, and E {111}<110> orientations, which changed to deformed texture Brass {110}<112> and Goss {011}<100> orientations in the middle region and cube texture at the bottom. Hardness was highest at the top region 5.33 GPa, followed by 4.02 GPa in the middle region and 4.74 GPa at the bottom. The COF was highest in the middle region at 0.456, which reduced to 0.323 in the bottom region. Sheared textured grains {111}<uvw> have shown greater value of COF and hardness than the {101}< uvw> and {100}<uvw> texture grains. The study has been carried out to investigate the variation in local mechanical properties due to microstructural variations. It will help industries to design components with homogeneous mechanical properties.

Stereolithography Printing and Mechanical Properties of Polyethylene Glycol Diacrylate/Hexagonal Boron Nitride Ceramic Composites

To enhance the mechanical properties of bioceramic composite bone scaffolds, a composite paste of polyethylene glycol diacrylate (PEGDA) and hexagonal boron nitride (h‐BN) with a solid content of up to 42 wt% was developed in this study. The part was produced using stereolithography (SLA). The SLA printing parameters and material ratios of the paste were optimized through a homogeneous design and mechanical property tests. The results indicate that the single‐line curing width of the PEGDA/h‐BN paste in the XY plane ranged from 172 to 209 μm, while the curing depth of a single layer along the Z‐axis ranged from 99 to 154 μm. Laser power was identified as the primary factor influencing both the width and depth of curing. The compressive strength of the printed sample of PEGDA/h‐BN ceramic composite paste was measured at 222.4 ± 5.6 MPa, which is 61 times greater than the compressive strength of a pure PEGDA structure and comparable to that of cortical bone (100‐230 MPa). Finally, the superior biocompatibility of PEGDA/h‐BN ceramics was confirmed through cytotoxicity experiments. Consequently, PEGDA/h‐BN ceramic composites meet the mechanical properties and biocompatibility requirements necessary for bone tissue applications, indicating promising potential in the field of bone tissue engineering.

Laboratory Earthquakes Simulations—Emergence, Structure, and Evolution of Fault Heterogeneity

AbstractSeismic faults are known to exhibit a high level of spatial and temporal complexity, and the causes and consequences of this complexity have been the topic of numerous research works in the past decade. In this paper, we investigate the origins and the structure of this complexity by considering a numerical model of laboratory earthquake experiment, where we introduce a fault with homogeneous mechanical properties but allow it to evolve spontaneously to its natural level of complexity. This is achieved by coupling the elastic deformability of the off‐fault medium (and therefore allowing for heterogeneous stress fields to develop) and the discrete degradation and gouge formation at the fault plane (and therefore allowing for structural heterogeneity to develop). Numerical results show the development of persistent stress, damage, and gouge thickness heterogeneities, with a much larger variability in space than in time. Strong positive correlations are found between these quantities, which suggest a positive feedback between local normal stress and damage rate, only mildly mitigated by the mobility of the granular gouge in the interface. For a wide range of confining stresses, after a sufficient number of seismic cycles, the fault reaches a state of established disorder with a constant roughness, a certain amount of periodicity at the millimetric scale, and a power law decay of the Power Spectral Density at smaller spatial scales. The typical height‐to‐wavelength ratio of geometrical asperities and the correlations between stress and damage profiles are in good agreement with previous field or lab estimates.

Effect of Thermomechanical Processing on the Transformation Kinetics, Microstructure and Mechanical Properties of a Continuously Cooled Cementite-free Bainitic Steel

Abstract The combination of forming with continuous cooling bainitic steels offers a new path for reaching energy-efficient manufacturing chains. Improved energy efficiency is achievable thanks to the suppression of conventional, energy-intensive heat treatments. In the present paper, different thermomechanical processing strategies, including laboratory and industrial scale forgings, were assessed alongside their impact on the resulting microstructure. Firstly, phase transformation kinetics were assessed in precisely controlled environments via dilatometry coupled to in situ techniques. Secondly, the microstructure, mechanical properties, and forgeability of large-scale forged components were investigated in laboratory and industrial conditions. These investigations were also assisted by finite element method simulation. The comparison between controlled and industrial-scale conditions illustrates pitfalls in the transfer of knowledge to conditions approaching a real manufacturing chain. Nevertheless, alloy and process design is shown to be a key aspect to overcome the discussed challenges, allowing homogeneous bainite microstructures and mechanical properties to be achievable over a flexible range of processing conditions.

Effect of multipass submerged friction stir processing on the microstructure, mechanical properties and corrosion resistance of 5383Al alloy

The 5383Al alloy is commonly used as a hull material because of its excellent mechanical properties, corrosion resistance and weldability. Nevertheless, the presence of coarse Al6(Fe, Mn) particles and the aggregation of the β phase at the grain boundaries noticeably diminish the corrosion resistance of 5383Al, even though they improve its mechanical properties somewhat. In the present study, multipass submerged friction stir processing (M-SFSP) was conducted on 5383Al alloy to precisely control the microstructure while maintaining a balance between mechanical performance and corrosion resistance. The effects of M-SFSP on the microstructure, mechanical properties and corrosion resistance of the 5383Al were investigated. The results show that homogenous ultrafine equiaxed grains of around 0.65 μm in size was acquired in the M-SFSPed zone through dynamic recrystallization. In the M-SFSPed zone, the dislocation density decreased and the proportion of high-angle grain boundaries increased. As a result, the M-SFSPed 5383Al alloy exhibited excellent and homogeneous mechanical properties, including an ultimate tensile strength of up to 400 MPa, comparable to that of the base material (BM). In addition, many fine Al6(Fe, Mn) particles were uniformly distributed in the M-SFSPed zone, and no β-Al3Mg2 phase was detected at the grain boundaries in the M-SFSPed zone. The M-SFSPed samples showed considerably lower mass loss to corrosion than the BM (1.8 mg/cm2 vs. 42.8 mg/cm2), indicating that M-SFSP increased the corrosion resistance of the 5383Al alloy through microstructure control. This improvement was attributed to the refinement of the Al6(Fe, Mn) phase and the redissolution of the β-Al3Mg2 phase, which effectively inhibited the spread of corrosion. Thus, M-SFSP is considered as a promising method for the manufacturing of 5383Al with high strength and outstanding corrosion resistance.

The tensile strength of brittle diamond lattice structure with material dispersion

Abstract This work investigates the effect of material dispersion on the tensile strength of brittle diamond lattice structure. In actual lattice structures fabricated by additive manufacturing, the dispersion of strength comes from microscale defect, geometric deviation and manufacture-induced anisotropy. The weakening of ultimate failure strength due to material dispersion cannot be predicted by most existing theoretical models, because they assume homogeneous and determinate mechanical properties of the lattice structure. In this paper, we employ diamond lattice structure made from brittle material as a typical example, and its tensile behavior is numerically investigated by incorporating the Gaussian distribution of strut strength. Inspired by the simulation results, a stochastic theoretical model is developed to predict the deformation and failure of diamond lattice structure with material dispersion. This model captures the fact that weaker struts break first even if the whole structure can still bear load. With the continuous increase of stress, these broken struts accumulate into continuous cracks, and ultimate failure occurs when the energy release rate of the initiated crack surpasses the intrinsic fracture toughness of the lattice structure. This research supplements stochastic feature into classical theories, and improves the understanding of potential strengthening and toughening designs for lattice structures.

Thermal cycling effects on the local microstructure and mechanical properties in wire-based directed energy deposition of nickel-based superalloy

In additive manufacturing, intrinsic heat treatments take place during deposition that affect the properties of AM-structures. In this work, the influence of thermal cycling on the local microstructure and mechanical properties of nickel-based superalloy in wire-based electron beam directed energy deposition (EB-DED) was investigated. Structures were fabricated using a continuous deposition strategy (CDS) and discontinuous interpass cooling strategy (ICS) revealing changes in thermal profiles, time-temperature history, and microstructure. An altered morphology along the build-up height and interdendritic zones enriched in Nb are formed. Nb and Mo did not show a clear trend of segregation along the build-up height. Lower fractions of the Laves phase and MCs are found for both configurations. Differences between deposition strategies and locations within AM-structures are found for the γ" and δ phase. The higher Nb content in the interdendritic zone promotes the precipitation of γ" and δ phase by shortening the aging times compared to wrought materials. The longer deposition times of ICS favour the precipitation of fine γ" in the interdendritic zone throughout the deposition height. In contrast, the short deposition time of CDS leads to an increase in temperature and a heterogeneous distribution of γ" along the height, i.e. coarsening of the γ" followed by a dissolution along the built-up height. The microstructural changes correlate with the mechanical properties. Structures fabricated with ICS exhibit homogeneous mechanical properties throughout, while the graded microstructure of CDS results in graded mechanical properties and decreasing strength throughout.

A superplastic micro-extrusion technology to develop engineered magnesium micro-components

Superplastic micro-extrusion (SME) is a state-of-the-art micro-manufacturing technology that produces intricate shape miniaturized components. Magnesium and its alloys (Mg alloys) are potential contenders for the miniaturization industries due to their lightweight and biocompatibility properties. SME is a promising solution to overcome the room temperature ductility/formability concerns in Mg alloys. Therefore, for the first time, the current work proposes superplastic micro-extrusion technology to manufacture high-performance Mg-RE alloy (QE22) based micro-components. The desirable ultrafine grain (UFG) microstructure suitable for superplasticity is synthesized/engineered and further subjected to two modes of superplastic micro-deformation: (1) micro-forward extrusion (MFE) and (2) micro-backward extrusion (MBE) in pre-optimized extrusion conditions. The test results revealed a uniform hardness profile throughout the developed miniaturized micro-pin and micro-cup. Such homogeneous mechanical properties of the developed micro-components can be attributed to the microstructural engineering and high thermal stability of the developed material especially engineered for the current superplastic micro-extrusion processes. Microstructural analysis in all the conditions linked this distinctive characteristic to the activation of grain boundary sliding (GBS) and its accommodative micro-mechanisms. The physics and fundamental science of superplastic microforming in both micro-forward and micro-backward extrusion domain is established for the engineered Mg-RE alloy. Such investigations on understanding the fundamental mechanisms can address the existing challenges in micro-manufacturing industries.

Combined First-Principles and Experimental Study on the Microstructure and Mechanical Characteristics of the Multicomponent Additive-Manufactured Ti-35Nb-7Zr-5Ta Alloy.

New β-stabilized Ti-based alloys are highly promising for bone implants, thanks in part to their low elasticity. The nature of this elasticity, however, is as yet unknown. We here present combined first-principles DFT calculations and experiments on the microstructure, structural stability, mechanical characteristics, and electronic structure to elucidate this origin. Our results suggest that the studied β Ti-35Nb-7Zr-5Ta wt % (TNZT) alloy manufactured by the electron-beam powder bed fusion (E-PBF) method has homogeneous mechanical properties (H = 2.01 ± 0.22 GPa and E = 69.48 ± 0.03 GPa) along the building direction, which is dictated by the crystallographic texture and microstructure morphologies. The analysis of the structural and electronic properties, as the main factors dominating the chemical bonding mechanism, indicates that TNZT has a mixture of strong metallic and weak covalent bonding. Our calculations demonstrate that the softening in the Cauchy pressure (C' = 98.00 GPa) and elastic constant C̅44 = 23.84 GPa is the origin of the low elasticity of TNZT. Moreover, the nature of this softening phenomenon can be related to the weakness of the second and third neighbor bonds in comparison with the first neighbor bonds in the TNZT. Thus, the obtained results indicate that a carefully designed TNZT alloy can be an excellent candidate for the manufacturing of orthopedic internal fixation devices. In addition, the current findings can be used as guidance not only for predicting the mechanical properties but also the nature of elastic characteristics of the newly developed alloys with yet unknown properties.

Numerical Modeling and Experimental Study of Solidification Behavior of Al-Mg2Si Composite Sheet Fabricated Using Continuous Casting Route

Abstract Owing to manufacturing challenges, the fabrication of thin sheets of metal matrix composites has been an area of concern for sheet manufacturers. Converting a billet of composite into a sheet using rolling and extrusion is quite energy-intensive and prone to cracking using the conventional casting route. To address this issue, this study explores the development of particle-reinforced near eutectic Al-Mg2Si composite sheets using a vertical twin-roll continuous casting process. The numerical simulation involves fluid flow, solidification, and heat transfer analysis of the twin-roll continuous casting process for producing thin strips. Processing parameters such as the velocity of rolls and superheat temperature of the melt are optimized to successfully convert the melt into a sheet of composite material. A combined numerical and experimental study show that the continuous casting process is more sensitive to the casting speed. A small change in roller speed (2 rpm) significantly affects the solidified fraction at the roller exit. Optimizing the casting speed to 0.072 m/s and inlet temperature to 886 K, an in situ Al-Mg2Si composite sheet of 3 mm thickness is successfully cast. The particle distribution along the casting direction of the sheet is uniform, ensuring the homogeneous mechanical properties reported in terms of hardness. The entire process does not require external stirring to get uniform distribution of the reinforced particles.

Geological-technical study for the design of an underground variant of S.S. 52 “Carnica” in the Passo Mauria area (Carnic Alps)

This study aims to define a preliminary geological model of the Passo Mauria tunnel, designed as an alternative underground route to the current S.S.52 to ensure a safer connection over the top way Belluno (A27 Highway) Tolmezzo (A23 Highway), on which various tourist and economic activities revolve. The survey stage has allowed us to describe and represent the cartographic elements that describe the geology of the study area. The study has mainly focused on the investigation of the presumed entrances of the tunnel, characterized by specific geological and geomorphological conditions. The aerial photogrammetric survey supported the reconstruction of the geometry of discontinuities in the non- accessible areas. Besides, this study has allowed the definition of the possible behaviour of the rock mass subjected to the tunnel excavation and of sections with homogeneous mechanical properties. The drafting of a survey plan supplements the study to determine a geological and geotechnical model, for the subsequent investigation and design phases.

Prediction of the optimal vulcanization of a fiber‐reinforced elastomeric isolator made of natural rubber‐ethylene propylene diene monomer blend

AbstractTo seismically isolate a structure, it is possible to interpose a rubber device between the foundation and superstructure that increases the period of the superstructure, a feature that allows the structure to be “transparent” to the seismic excitation. A package of several rubber pads typically constitutes a seismic isolator; they are 10–20 mm thick vertically interspersed with either steel laminas or fiber‐reinforced polymer dry textiles suitably treated. So, the rubber has a primary role and must be vulcanized correctly to create the polymer cross‐linking properly. All rubber mechanical properties are strongly affected by curing temperature and curing time. Under vulcanization is a typical production error that suppliers make in large‐scale productions, especially when the size of the devices is considerable. It is common to deal with elastomeric isolators where rubber pads have been treated at a largely suboptimal temperature. This article proposes a numerical model for predicting the cross‐linking degree of rubber pads used in seismic isolation and made by a natural rubber‐ethylene propylene diene monomer rubber compound. The aim is to correctly define the optimal curing temperature and exposition time for producing a rubber quadruple shear test specimen and a fiber reinforced elastomeric isolator (FREI). The model is a kinetic one and takes into consideration the induction time. An experimental investigation has been conducted to validate the model with visible inspections and hardness measurements taken on the rubber pads (quadruple shear specimens) and the rubber devices. The results have shown the reliability of the new numerical model proposed, with a homogeneous mechanical properties distribution obtained within the rubber pads and the FREI.

Evolution of near homogenous mechanical and microstructural properties in wire-arc based directed energy deposition of low carbon steel following trochoidal trajectory toolpath

In the present work, the application of wire-arc-based directed energy deposition (DED) for the building up of three-dimensional structures of low-carbon steel (ER70S6) is proposed. The classical trochoidal-trajectory-based toolpath is employed to rapidly build up the structures with near homogeneous mechanical properties of the built. A robust as well as simple methodology has been developed, which is capable of building up thick walls of height 5 − 6 mm and width ∼ 20 − 22 mm in a single pass. During the deposition process, a uniform and fine distribution of grains with degenerate pearlite phases revealed, which is not usual in the layer-by-layer deposition of low-carbon steel. The trochoidal trajectory of the toolpath leads to the reheating of the deposition layer at 900 K and results in the formation of degenerate pearlite. The Electron Back Scatter Diffraction (EBSD) analysis confirms the formation of homogeneous and equiaxed grains of size 8μm throughout the built part. The mechanical properties of the built-up part improved with a uniform hardness of ∼174 HV and tensile strength of ∼ 494 MPa. Even, 40% elongation and 48.7% better wear resistance with respect to the base material are achieved for the deposited wall in different directions. This work presents a novel methodology to achieve near isotropic propery of arc-based DED process.

Behaviour of hybrid cross laminated timber in compression perpendicular to grain in different layup structure, support conditions, and loading configurations

Cross laminated timber (CLT) is recognized as alternative to traditional construction materials. As a floor member, it causes the compressive deformation or even damage perpendicular to the grain of CLT due to vertical load imposed by the column or wall. The challenge is how to improve the compressive strength (fc,90) and elastic modulus (Ec,90) perpendicular to the grain under the high diversity of possible load configurations. Compared with normal CLT, hybrid CLT (HCLT) used structural composite materials (e.g. laminated strand lumber) instead of timber, which had more homogeneous mechanical properties. In this study, the spruce-pine-fir (SPF) and laminated strand lumber (LSL) were used to prepare HCLT. The full surface loading, point loading representing columns and line loading representing walls of HCLT in the perpendicular to grain direction were carried out. The results show that fc,90 increased with increasing thickness ratio of LSL in the total thickness of HCLT under full surface loading, the highest increase in strength of HCLT reached 35.71 %, data of Ec,90 had the opposite conclusion. In the case of point loading, the fc,90 and Ec,90 under discretely support was lower than those under successively support. Load configuration had significant influence on the fc,90 and Ec,90 including middle position (M), corner position (C), edge parallel (E) and edge vertical (V) to the grain of the outer layer. In the case of line loading, it was in good agreement with point loading results, and fc,90 and Ec,90 under line loading were lower than that under point loading. The failure modes were mainly the cracks along the wood ray direction of SPF material, while no obvious damage for LSL under full surface loading. In addition, the failure modes mainly of local loading included the shear failure for SPF material, fiber fracture failure of LSL material and the adhesive layer cracking in the non-directly compression zone.

Matching mechanical heterogeneity of the native spinal cord augments axon infiltration in 3D-printed scaffolds

Scaffolds delivered to injured spinal cords to stimulate axon connectivity often match the anisotropy of native tissue using guidance cues along the rostral-caudal axis, but current approaches do not mimic the heterogeneity of host tissue mechanics. Although white and gray matter have different mechanical properties, it remains unclear whether tissue mechanics also vary along the length of the cord. Mechanical testing performed in this study indicates that bulk spinal cord mechanics do differ along anatomical level and that these differences are caused by variations in the ratio of white and gray matter. These results suggest that scaffolds recreating the heterogeneity of spinal cord tissue mechanics must account for the disparity between gray and white matter. Digital light processing (DLP) provides a means to mimic spinal cord topology, but has previously been limited to printing homogeneous mechanical properties. We describe a means to modify DLP to print scaffolds that mimic spinal cord mechanical heterogeneity caused by variation in the ratio of white and gray matter, which improves axon infiltration compared to controls exhibiting homogeneous mechanical properties. These results demonstrate that scaffolds matching the mechanical heterogeneity of white and gray matter improve the effectiveness of biomaterials transplanted within the injured spinal cord.

The influence of a large build area on the microstructure and mechanical properties of PBF-LB Ti-6Al-4 V alloy

This study investigated the print homogeneity of Ti-6Al-4 V alloy parts, when printed over a large build area of 250 times 250 times 170 mm3, using a production scale laser powder bed additive manufacturing system. The effect of part location across this large build area was investigated based on printed part porosity, microstructure, hardness, and tensile properties. In addition, a Hot Isostatic Pressing (HIP) treatment was carried out on the as-built parts, to evaluate its impact on the material properties. A small increase in part porosity from 0.01 to 0.09%, was observed with increasing distance from the argon gas flow inlet, which was located on one side of the build plate, during printing. This effect, which was found to be independent of height from the build plate, is likely to be associated with enhanced levels of condensate or spatter residue, being deposited at distances, further from the gas flow. Despite small differences in porosity, no significant differences were obtained for microstructural features such as prior β grain, alpha lath thickness, and phase fraction, over the entire build area. Due to this, mechanical performances such as hardness and tensile strengths were also found to be homogenous across the build area. Additionally, it was also observed based on the lattice constants that partial in-situ decomposition of {alpha }^{^{prime}}to alpha +beta phases occurred during printing. Post HIP treatment result showed a decrease of 7 and 6%, in the yield strength (YS) and ultimate tensile strength (UTS), respectively, which was associated with a coarsening of alpha lath widths. The potential of the laser powder bed system for large area printing was successfully demonstrated based on the homogenous microstructure and mechanical properties of the Ti-6Al-4 V alloy parts.

Structure-property correlation of a CoCrFeNi medium-entropy alloy manufactured using extreme high-speed laser material deposition (EHLA)

A near-dense and crack-free CoCrFeNi medium entropy alloy (MEA) coating was fabricated using extreme-high-speed laser material deposition (EHLA). The ultra-low local heat input associated with the EHLA process benefitted in attaining minimal dilution and heat-affected zone. The MEA coating retained the single-phase face-centered cubic (FCC) phase structure associated with the original powder feedstock without any evidence of elemental segregation. The coating exhibited a “bonfire”-like clustered fine grain structure near the substrate interface with the large columnar grains in the subsequent layers further from the substrate. Anisotropic mechanical deformation behaviour was observed at a localized level, but homogenous mechanical properties were evidenced by microstructure-mechanical property correlations at the bulk level. The EHLA process offers exciting possibilities for the development of next-generation dense and crack-free coatings for extreme engineering applications.

Investigation of the Mechanical Properties for Polymer Reinforced by Nanoparticles with Considering Viscoelasticity of the Matrix

Investigation of the Mechanical Properties for Polymer Reinforced by Nanoparticles with Considering Viscoelasticity of the Matrix

The effects of alloying composition on plasticity and strength of notched metallic glasses

Using notch geometry in the metallic glass (MG) samples, it is possible to improve the homogeneous plasticity and mechanical properties. In this work, the molecular dynamics (MD) simulation was performed to indicate how the alloying composition of MGs can tune the mechanical properties of notched samples. For this purpose, CuZr MGs were constructed through atomic-scale simulation with alloying compositions of Cu64Zr36, Cu60Zr40, Cu54Zr46, and Cu50Zr50, while a symmetrical surface notch was produced at the waistline of samples by removing certain atoms and relaxing the new free surfaces. The tensile loading was also carried out to characterize the plastic deformation and strength in the CuZr MGs. According to the results, Cu64Zr36 and Cu60Zr40 alloys exhibited a localized plastic deformation in the notch region, while the decrease in Cu content, i.e. Cu54Zr46, led to the generation of nanoscale shear events outside the notch region and extended the deformation area in the body of the sample. The results also indicated that the change in the mechanism of plastic deformation in the notched samples strongly depended on the type and population of polyhedrons rearranged in the backbone structure. Moreover, it was found that the Voronoi volume in the Cu54Zr46 alloy exhibited a gentle increment under the tensile loading in both the notched and un-notched regions, while the Cu-rich MGs, i.e. Cu64Zr36 and Cu60Zr40, showed a sudden increment of Voronoi volume at the center of the notch region, which was indicative of strain localization in the atomic system.

Evolution of material properties during the solvent-assisted recycling of thermosetting polymers: to reduce the residual stress and material inhomogeneity

Primary recycling of thermosetting polymers is shown to be enabled by depolymerizing the material in a suitable organic solvent and then re-polymerizing it into near-identical networks with equivalent mechanical properties. The re-polymerization process involves sophisticated coupling among solvent diffusion, chemical reaction, and stress field development. Specifically, solvent evaporation leads to restrained volume shrinkage of the resin and residual stress development within the re-polymerized materials. Nonuniform curing degree and material properties are also developed in the direction of solvent diffusion. These impose grand challenges to identify the optimal processing conditions to recycle thermosets with high quality and high speed. In this paper, using an integrated experimental and theoretical approach, the evolutions of the stress field and material properties during the re-polymerization of thermosetting polymers are studied. It shows how to tune the processing temperature to mitigate the residual stress and material inhomogeneity of recycled thermosets. The influencing mechanisms of sample thickness and catalyst content are also revealed. The fundamental understanding is finally extended to study the manufacturing of composites with particle reinforcements using the depolymerized solution, with a particular emphasis on the minimization of the stress concentration around particles. Overall, this study provides a guideline to design material and processing conditions for homogeneous network structure and mechanical properties of recycled thermosets, which will promote the applications of the green recycling method for thermoset wastes and benefit society.