Improvement Of Mechanical Properties Research Articles

Unprecedented high-strength and ductility in Ni nanograined metal via minor phosphorus alloying

A bulk Ni nanograined (NG) metal with 2 at.% P alloying was synthesized via electrodeposition, leading to notable improvements in mechanical properties compared to its NG Ni counterpart. The reduction in grain size from 104 nm to 45 nm, accompanied by a remarkable increase in yield strength from 620 MPa to 1550 MPa, signifies the efficacy of phosphorus (P) incorporation. Remarkably, the ductility of NG Ni-P remains robust at 16 %, comparable to NG Ni. These enhancements stem from the synergistic effects of P, which not only refine grain size but also promote the formation of a dense network of growth stacking faults, dislocations, and growth twins within the as-deposited NG Ni-P structure.

Simultaneous improvement in mechanical properties, corrosion resistance and antibacterial properties of Ti-Ag sintered alloy with gradient nanostructure

Bioinert titanium (Ti) with antibacterial properties is crucial for bone implantations. Alloying Ag can endow Ti with antibacterial properties, while the mechanical, corrosion and antibacterial properties of Ti-Ag alloys are not satisfactorily balanced. In this work, Ti-x wt%Ag alloys (x=0.5, 1 and 3) were sintered by spark plasma sintering and then subjected to a surface mechanical rolling treatment (SMRT). The Ti-Ag alloys are composed of Ti, Ti-Ag and Ti2Ag phases. After SMRT, a gradient nanostructured (GNS) layer formed on the Ti-Ag surface, the mean grain size is ∼ 6 nm at the top surface and increases gradually with depth. The GNS layer endows Ti-Ag alloys with better wettability, higher nano-roughness and compressive residual stress. Incorporating limited Ag (≤1 wt%) in Ti can effectively enhance its mechanical (surface hardness, wear resistance and compressive strength) and anti-corrosion properties, and they can be further improved by forming a GNS layer. The antibacterial efficiency of Ti-Ag is positively proportional to Ag content, and they are significantly enhanced after surface nanocrystallization. The bacteriostatic mechanism is the synergistic interaction between leach Ag+ and nano Ag-containing phases of GNS Ti-Ag alloy. Both Ti-Ag and GNS Ti-Ag alloys possess good cytocompatibility, the GNS layer has the potential to encourage early differentiation of osteoblasts. The GNS Ti-Ag alloy with 1 wt% Ag has excellent comprehensive properties, which shows larger potential in orthopedic applications.

Comparison of copper-based composites fabricated by cross-accumulative roll bonding method for packaging design

Copper-based composites have interesting properties and they are widely used in electronics, packaging, and automotive applications. In the present work, the cross-accumulative roll bonding (CARB) process was used to fabricate Cu-based composites with Zn and Brass reinforcing layers. The experimental observations revealed a clear relationship between rolling strain and plastic instabilities including the necking and rupture of reinforcement. However, the grain refinement was observed on Cu, Zn, and Brass layers after seven CARB cycles, indicating the positive impact of rolling rotation on obtaining the ultrafine grains. Better ductility of Brass also resulted in finer grains. This also led to more significant improvement in mechanical properties. During the CARB process, the hardness of Zn and Brass increased from 59 HV and 250 HV to 89 HV and 310 HV, respectively.

Chitosan-ginger essential oil nanoemulsions loaded gelatin films: A biodegradable material for food preservation

The alarming issue of food waste, coupled with the potential risks posed by petroleum-based plastic preservation materials to both the environment and human health necessitate innovative solutions. In this study, we prepared nanoemulsions (NEs) of chitosan (CS) and ginger essential oil (GEO) and systematically evaluated the effects of varying NEs concentrations (0, 10 %, 30 %, 50 %) on the physicochemical properties and biological activities of gelatin films. These films were subsequently applied to blueberry preservation. The scanning electron microscopy confirmed that the NEs were well-integrated with the Gel matrix, significantly enhancing the performance of the Gel films, including improvements of mechanical properties (tensile strength from 7.71 to 19.92 MPa; elongation at break from 38.55 to 113.65 %), thermal, and barrier properties (water vapor permeability from 1.52 × 10−9 to 6.54 × 10−10 g·m/Pa·s·m2). The films exhibited notable antibacterial and antioxidant activities due to the gradual release of GEO, thereby extending the storage life of blueberries. Moreover, the prepared composite films demonstrated excellent biodegradability and environmental friendliness, with the majority of the material decomposing within 30 days under soil microbial action. In conclusion, the active films loaded with NEs exhibit superior performance and hold significant potential for developing biodegradable materials for food preservation.

Bio-inspired synthesis of nanocrystalline calcite demonstrating significant improvement in mechanical properties of concrete: a construction-nanobiotechnology approach.

The bioinspired synthesis of construction material, known as biocement, represents a significant advancement in addressing the environmental sustainability issues associated with traditional cement use in the built environment. Biocement is produced through the process of microbially induced bio-mineralization (MIBM), which offers a promising alternative or supplement to conventional cement, potentially reducing its consumption. Despite extensive literature on the application of biocement in construction biotechnology, the fundamental mechanisms underlying its ability to enhance concrete quality remain poorly understood. This study focuses on the kinetics of biomineral synthesis by two Bacillus species; Bacillus megaterium RB05 and Bacillus foraminis DRG5, to identify the most effective strain for biomineralization. Bioconcrete specimens were created by adding inoculum containing Bacillus megaterium RB05 cells with a nutrient solution to the concrete mixture in a layer-by-layer approach. After 28days of water curing, nanoparticles of CaCO3, ranging in size from 27 to 82nm, were produced in the bioconcrete specimens. The resulting concrete, containing nanocrystalline biogenic calcite, demonstrated significant improvements in mechanical properties. Specifically, compressive and tensile strengths of the bioconcrete, tested using a universal testing machine (UTM), increased by 7.69 ± 0.08% and 22 ± 0.1%, respectively, after 72h of curing. Additionally, the biocement was found to exhibit an organic-inorganic hybrid nature, as identified by TEM, EDAX, FESEM, FTIR, and XRD analyses. The enhanced mechanical properties were attributed to the high surface-to-volume ratio and hybrid nature of the calcite nanoparticles. The findings of this investigation are encouraging, suggesting the potential development of future green and self-sustainable construction materials or bioconcrete.

FABRICATION OF AA1100/Fl2O3 COMPOSITE STRIPS AND THE IMPROVEMENT OF THEIR ELECTROMAGNETIC, MECHANICAL AND FRACTURE PROPERTIES

In this study, forming limit diagrams (FLDs), fracture toughness (FT), mechanical, magnetic, and electro-physical properties of Al/Fe2O3 composites have been investigated experimentally. Accumulative-roll-bonding (ARB) process was used to manufacture composite samples. Then, Al/Fe2O3 composites have been produced at 300∘C up to eight ARB passes. Also, magnetic composites have been fabricated with 0, 5% and 10[Formula: see text]wt.% of particles. The interlayer bonding quality was improved at higher passes. By studying the SEM rapture morphology, it was shown that the rapture mode changed to shear ductile for samples with more passes. For composite samples fabricated at higher passes and in comparison with the annealed sample, elongated dimples were turned to shallow dimples. FLDs area as the main forming criterion dropped severely after pass one and then began to improve at higher passes. Fracture test results showed that after the 8th pass, the value of FT improved gradually to the maximum value of 34.3[Formula: see text]MPam[Formula: see text].

Characterization and optimization of desulfurized construction gypsum modified with functionalized nanocellulose

This study focuses on the development and characterization of a novel composite material based on flue gas desulfurization (FGD) gypsum modified with functionalized nanocellulose. The incorporation of 0.1 wt% nanocellulose into the FGD gypsum matrix resulted in significant improvements in mechanical strength, water resistance, and thermal insulation properties. The flexural and compressive strength of the optimized composite increased by 32 % and 27 %, respectively, compared to the control sample. The water absorption decreased by 22 %, and the softening coefficient increased from 0.72 to 0.85, indicating enhanced water resistance. The thermal conductivity of the composite was reduced by 31 %, showcasing its potential as an energy-efficient building material. SEM analysis revealed a refined microstructure with improved interfacial bonding between the nanocellulose and gypsum matrix, while FTIR spectroscopy confirmed the presence of chemical interactions between the components. The moisture buffering capacity of the composite was also superior, with a 38 % higher moisture buffering value than the control sample. These findings highlight the potential of functionalized nanocellulose as a reinforcing agent in FGD gypsum-based composites, offering a promising solution for the development of high-performance, eco-friendly building materials.

Preparation of fine-grained/ultrafine-grained Nb521 alloy with superior mechanical property by friction stir processing

High strength-ductility synergy is difficult to achieve in Nb alloys. Although high strength has been achieved through severe plastic deformation (SPD) technology, led to low ductility in alloys. In this work, FSP technology was applied to treat Nb–5W–2Mo–1Zr-0.1C (Nb521) alloys in preparation of fine-grained (FG)/ultrafine-grained (UFG) Nb521 with excellent strength and ductility. The microstructure evolution and mechanical property improvement mechanism were systematically studied for Nb521 alloy through various characterization pathways. The research results indicated that UFG Nb521 alloy with a grain size of 0.63 ± 0.41 μm can be prepared using low shoulder plunge depth FSP (LPD-FSP), which is the first report of UFG Nb521 alloy. The main reason for the formation of onion rings structure in SZ is the periodic wear of the stirring tool, and the onion rings structure does not cause mechanical damage. The texture formed by Nb521 alloy under different processing parameters is off-axis shear texture, which matches the ideal shear texture of D2 (112‾)[111] after rotation. In addition, this study also elaborated on the refinement mechanism of the second phase particles (Nb, Zr) C in Nb521 alloy during FSP. This study also indicated that the increase in yield strength of FSP samples at room temperature is mainly determined by grain refinement. These findings provided new ideas for the development of high-performance niobium alloys.

Mechanical and shrinkage properties of cellulose nanocrystal modified alkali-activated fly ash/slag pastes

Alkali-activated materials based on fly ash (FA) and ground granulated blast furnace slag (GGBFS) offer lower carbon footprints but face challenges like low tensile strength and shrinkage susceptibility. This research explores the potential of cellulose nanocrystals (CNC) as additives to enhance the mechanical and shrinkage properties of alkali-activated fly ash/slag (AAFS) pastes to advance sustainable construction materials. A comprehensive examination is conducted on the impact of different contents of CNC (0.05 %, 0.1 %, 0.2 %, and 0.3 % by mass of FA + GGBFS) on the properties of AAFS pastes with two different alkaline activator contents (4 % and 8 % by mass of FA + GGBFS). It is found that incorporating 0.3 % CNC into AAFS pastes respectively improves the 28-day compressive and flexural strengths by 18.54 % and 60.87 % (8 % alkaline activator) and by 16.99 % and 50.12 % (4 % alkaline activator), and reduces the autogenous shrinkage and drying shrinkage by 26.42 % and 50.32 % (8 % alkaline activator) and by 11.74 % and 22.05 % (4 % alkaline activator). Also, the flexural/compressive strength ratio of AAFS pastes is increased with increasing CNC content. The microstructural analysis shows increased hydration product formation and a smoother, more compact morphology in CNC-modified samples, which together with water retention and distribution effect and nano-reinforcing effect of CNC explains the improvements in mechanical properties and volume stability. The research findings highlight the great potential of CNC as a reinforcing agent for sustainable construction materials, aligning with the demand from industries for eco-friendly alternatives to traditional cementitious materials.

Using pulse current to tailor hydride networks while improving the strength and plasticity of pure titanium

Interstitial hydrogen atoms in titanium usually deteriorate the mechanical properties of titanium by brittle hydride phase or hydrogen-enhanced localized plasticity. In this study, hydride was used as the second phase to improve the tensile strength and elongation of TA1 pure titanium. The continuous coarse hydride network is precipitated in TA1 pure titanium after the hydrogen-charged. Then pulse current treatment is used to decompose the original coarse hydride network and reduce the size and number of hydride strips. Finally, a small uniform hydride network is formed in TA1 pure titanium. The results of tensile experiments indicate that the tensile strength of hydrogen-charged TA1 pure titanium treated by pulse current increases from the 286.4 MPa to 316.1 MPa and the elongation increases from the 47.6 % to 56.8 %. The improvement of mechanical properties demonstrate that the small and uniform hydrides can significantly improve the mechanical properties of TA1 pure titanium. In hydrogen-charged TA1 pure titanium treated by pulse current, the increment of strength is mainly caused by hard phase hydrides, and the increase in plasticity is attributed to the role of twins in coordinating deformation during plastic deformation. This study manifests that in addition to being used as a temporary alloying element to optimize the microstructure of titanium, hydrogen can also be directly act as a second phase in titanium to improve the mechanical properties.

Effects of plasma electrolytic polishing on the surface and mechanical properties of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si specimen fabricated by laser powder bed fusion

The high roughness of titanium alloy specimen fabricated by laser powder bed fusion (LPBF) may limit the application of LPBF technology. Plasma electrolytic polishing (PEP) can effectively reduce the surface roughness of metal samples. In this study, an orthogonal test was designed to investigate the effects of polishing time, voltage and electrolyte temperature on the reduction of roughness and wall thickness of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si specimens fabricated by LPBF. The surface roughness of the specimen decreased from Ra = 49.1 μm to Ra = 9.1 μm and the thickness decreased from 1.72 mm to 1.38 mm after the PEP. Due to the recoil pressure induced by rupture of vapor-gaseous envelope (VGE) and the annealing effect caused by electron impact, the width of α/α' grains on the surface of TC11 specimen decreased from 0.51 μm to 0.46 μm; the mean value of geometrically necessary dislocations (GND) increased by 9.8 %; the proportion of high angle grain boundaries (HAGBs) increased from 75.2 % to 80.8 %; the proportion of twin grain boundary length increased from 2.9 % to 11.9 %, and the activated twin variant type increased from 2 to 4. The number of pores in the samples reduced from 85 to 2 after PEP, which resulted in the improvement of tensile and fatigue properties. The ultimate strength and elongation of the tensile specimens increased by 6.2 % and 53.5 % respectively. The infinite fatigue life maximum stress of the high cycle fatigue specimen increased by 62.5 %. Another reason for the improvement of mechanical properties may be the self-healing of microcracks and the electroplasticity in the specimens.

Effect of interlayer ultrasonic impact on the microstructure, mechanical and corrosion properties of wire arc additive manufacturing AZ31 Mg alloy thin wall

AZ31 Mg alloy thin walls are prepared using wire arc additive manufacturing (WAAM) and interlayer ultrasonic impact (UI) techniques with cold metal transition (CMT) serving as the heat source. The microstructure, mechanical and corrosion properties of thin walls prepared by WAAM and WAAM + UI are studied. Results showed that the recrystallization area fraction along traveling direction (TD) increased by 68.6% after UI treatment, and many fine equiaxed crystals were formed, resulting in grain refinement, anisotropy reduction, mechanical and corrosion properties improvement. The average grain size along TD decreased from 66.6 ± 3.5 μm to 32.7 ± 1.6 μm. Through UI treatment, the ultimate tensile strength (UTS) and elongation (EL) along TD increased from 205 MPa to 230 MPa and 13.5%–17%, respectively. The anisotropic percentage of UTS and EL were decreased from 10.8% to 4.5%, and 42.1%–9.7%, respectively. Electrochemical experimental results showed that the average corrosion rate along TD decreased from 1.93 mm year−1 to 1.53 mm year−1. Grain refinement, dislocation density variation and texture strength reduction were the main reasons for these results.

Functionalization of Graphene Nanosheets-3D Printing Resins for Improvement of Mechanical Properties and Thermal Conductivity

Functionalization of Graphene Nanosheets-3D Printing Resins for Improvement of Mechanical Properties and Thermal Conductivity

Synthesis of bio-polyol-functionalized nanocrystalline celluloses as reactive/reinforcing components in bio-based polyurethane foams by homogeneous environment modification

Nanocrystalline Cellulose (NCC or CNC) is widely used as a filler in polymer composites due to its high specific strength, tensile modulus, aspect ratio, and sustainability.However, CNC hydrophilicity complicates its dispersion in hydrophobic polymeric matrices giving rise to aggregate structures and thus compromising its reinforcing action. CNC functionalization in a homogeneous environment, through silanization with trichloro(butyl)silane as a coupling agent and subsequent grafting with bio-based polyols, is herein investigated aiming to enhance CNC dispersibility improving the filler-matrix interaction between the hydrophobic PU and hydrophilic CNC. The modified CNCs (m_Ci) have been studied by XRD, SEM, and TGA analyses. The TGA results show that the amount of grafted polyol is strongly influenced by both its molar mass and OH number and the maximum amount of grafted polyol reaches up to 0.32 mmol per grams of functionalized CNC, within the explored conditions. The effect of different concentrations (1–3 wt%) of m_Ci on the physical, morphological, and mechanical properties of the resulting bio-based composite polyurethane foams is evaluated. Composite PU foams present compressive modulus up to 4.81 MPa and strength up to 255 kPa more than five times higher than those reinforced with unmodified CNC or with modified CNC in heterogeneous chemical environment. The improvement of mechanical properties of the examined PU foams, as a consequence of the incorporation of bio-polyols modified CNCs where polyol's OH groups interact with polyurethane precursors, could further broaden the use of these materials in building applications.

Evaluation of the performance enhancement of asphalt concrete via graphene oxide incorporation: A multi-test approach

The need for improved asphalt pavements has led to the exploration of nanomaterials such as graphene oxide (GO). This study investigates the potential of GO to enhance the performance of asphalt concrete (AC) with a nominal maximum aggregate size of 12.5 mm (AC_12.5) pavements, a commonly used material in highway construction that has not been extensively studied with GO modification. The main objective is to evaluate the impact of varying GO content (1%, 1.5%, and 2%) on the key technical properties of AC_12.5, including rutting resistance, moisture stability, and tensile capacity. A series of performance tests, including Marshall stability, residual stability, splitting tensile strength, and dynamic modulus, were conducted on AC_12.5 samples with varying GO content. Furthermore, a mechanistic– empirical (M-E) approach was employed to compare the rutting resistance of GO-modified pavements with that of conventional pavements. Initial findings suggest that GO incorporation significantly enhanced the mechanical properties of AC_12.5 compared with the control mixture. Performance tests indicated improved rutting resistance, moisture stability, and tensile capacity. The M– E analysis demonstrated superior rutting resistance in the GO-modified pavement structures. The findings confirm the potential of GO as a promising nanomaterial for enhancing the performance of AC_12.5 pavements. The observed improvements in key mechanical properties and rutting resistance suggest its feasibility for developing more durable, sustainable, and cost-effective roads in the future.

Atomistic insight into laser shock peening response of α-titanium: an experimentally verified simulation study

Laser shock peening (LSP) can induce severe plastic deformation in the surface zone of metallic materials, which potentially enhances their mechanical properties. Although it is widely recognized that the improvement of mechanical properties can be attributed to microstructure evolution, the microstructural characteristics and response under different LSP parameters are complex, leading to distinct mechanical behaviors of materials at the macroscale. Besides, the exceedingly brief duration of LSP also poses considerable challenges to capture the microstructure evolution within the surface layer of materials. Therefore, to grasp a first in-situ atomistic insight into LSP response of α-titanium, molecular dynamics method is applied to simulate laser incidence at the [101¯0] crystallographic orientation with various energy densities. The results show that the lattice reorientation and dislocation slip dominate the plastic deformation at low laser energy density, while stacking faults and crystal disordering are the primary microstructural features at high laser energy density. The above shock-induced microstructures are verified by transmission electron microscopy (TEM) observations. Further, varied microscale plastic deformation modes under varying shock energies are proposed based on Schmid factors and energy barriers. The findings bridge laser energy to post-processing microstructure of α-titanium, which paves the way for improving mechanical properties of materials by optimizing LSP treatment parameters.

Mechanical and thermal stability properties improvement of polyethylene wax-coated tungsten carbide/high-density polyethylene γ-rays shielding composites through irradiation-induced crosslinking

It is well known that the properties of polyethylene can be improved by irradiation-induced crosslinking the formation of three-dimensional network structures. This paper investigated the effects of gamma irradiation on the mechanical, thermal stability, and γ-rays shielding properties of TAIC-containing γ-rays shielding composites (HDPE/WC-PEW/TAIC). As a result, SEM images showed that agglomerations are alleviated after polyethylene wax (PEW) coated tungsten carbide (WC). The tensile strength and hardness increased from 25.39 MPa to 94 HA to 29.49 MPa and 98 HA after 50 kGy irradiation in vacuum as compared with all composites, while the thermal stability was also improved. The XPS and gel content results showed that the more crosslinked structures generated after 50 kGy irradiated in vacuum between high-density polyethylene (HDPE) and PEW, but irradiation in air is accompanied by the destruction of polymer skeleton. Moreover, the shielding rates of HDPE/WC-PEW/TAIC with thickness of 2 mm and containing 50 wt% WC can exceed 50% and 25% for 137Cs and 60Co sources respectively. In summary, HDPE/WC-PEW/TAIC could be an alternative to lead as γ-rays shielding material with excellent mechanical, thermal, and γ-rays shielding properties after 50 kGy irradiation in vacuum.

Regulating natural galactomannan into composite hydrogels for improved adhesion, anti-swelling capability and efficient dye pollution removal

Constructing bio-based composite hydrogel materials are receiving much interest, while regulating the interactions of the hydrogel components and integrating functions for multi-application meet various challenges. Herein, composite hydrogels were prepared by cross-linking of poly-acrylamide (PAM) and poly-N-[3-(Dimethylamino) propyl] acrylamide (PDMAPAA), assisted by natural galactomannan (GM) regulation. Even distribution and compatibility of GM in the three-dimensional materials were proved by a series of chemical and morphological characterizations, which favored the improvement of mechanical properties (~80 kPa) and flexibility. Besides, the hydrogels were well-connected with double networks of noncovalent intermolecular hydrogen bonding interactions and hydrophobic interactions, in addition to covalent-linked polymers. Due to great amount of inner hydrogen bond linkages, the hydrogels present satisfying anti-swelling capabilities (<15 %), exhibiting high potential for application in water treatment. Meanwhile, abundant surface functional groups provided possibilities to form interactive layer with the various substrates surface, exhibiting highly adhesive properties. Significant dyes adsorption capabilities were revealed on the hydrogels according to the electrostatic attraction with Congo red and hydrogen bond interactions with Brilliant green respectively. Thus, the proposed composite hydrogels integrated multi-functions due to the tuning the surface groups and cross-linking interactions, which provided deeper understanding on bio-based materials on fields of water treatment and environmental protection.

Preparation of Poly(Styrene-co-Acrylonitrile)-Grafted Attapulgite via Simultaneous Reverse and Normal Initiation Atom Transfer Radical Polymerization (SR&NI ATRP) and Its Effect on Polycarbonate/Acrylonitrile-Butadiene-Styrene Terpolymer Ternary Composites

To further improve the comprehensive properties of polycarbonate/acrylonitrile–butadiene–styrene terpolymer blends (PC/ABS), in this work, styrene–acrylonitrile copolymer [P(St-co-An)] was grafted on the surface of attapulgite particles (ATP) by simultaneous reverse and normal initiation ATRP (SR&NI ATRP) to yield ATP@P(St-co-An) hybrid particles. Then a series of PC/ABS/ATP@P(St-co-An) composites were prepared via the melt blending method. The effects of ATP@P(St-co-An) content on the morphological, mechanical, thermal and rheological properties of the composites were investigated in detail. The core-shell ATP@P(St-co-An) hybrid particles with the polymer layer thickness of 20-40 nm were synthesized successfully according to the results of X-ray photoelectron spectrometer (XPS), Fourier transform infrared spectrometer (FTIR), gel permeation chromatography (GPC), thermogravimetric analysis (TGA) and transmission electron microscopy (TEM). The improvement in mechanical properties, reduced glass transition temperature (T g) difference between PC and ABS and micromorphology changes of the composites proved the compatibilization, strengthening, and toughening effect of the ATP@P(St-co-An). Compared with the PC/ABS blend, with strength and toughness of 50.8 MPa and 56.3 kJ/m2, when the ATP@P(St-co-An) content was 4 wt%, a reasonable balance (85.8 MPa and 86.2 kJ/m2) between strength and toughness was achieved with substantially enhanced thermal stability. Moreover, the composite showed more remarkable non-Newtonian behavior, and its processability was also improved. We believe this work provides an effective approach to optimize the compatibility and comprehensive properties of PC/ABS blends.

Enhancing the performance of 3D-printed fiber-Reinforced mortar: synergistic effects of clays and bacterial cells as viscosity modifying agents

The absence of standardized 3D concrete printing mixtures drives ongoing material exploration. This study investigates mineral and bio-based viscosity modifying agents (VMAs) application in fiber-reinforced cementitious mortar. Nano-montmorillonite, sepiolite, and bacterial cells function as supplementary materials, partially substituting cement with fly ash for sustainability assessment and compatibility evaluation in our study. Mechanical tests encompass compressive, flexural strength, and interlayer bonding in 3D-printed samples. Based on the results, incorporating 0.150% Polyamide (PA) fiber positively affected interlayer bonding strength and deceleration of the flow loss rate. Additionally, adding clays decreased workability and compressive strength but improved interlayer bonding and flexural properties. On the other hand, substituting 20% of cement with FA improved the flowability of the mixture and showed great compatibility with other materials during printing. Applying a cement paste layer was evaluated as a practical method for bond enhancement at the interface. Bacteria incorporation improved flexural strength but weakened interlayer bonding. However, the combination of bacteria and clays resulted in a superior improvement in mechanical properties. This study demonstrates clays and bacteria’s potential in enhancing rheological and mechanical features in cementitious fiber-reinforced mortar. Notably, this study introduces bacteria cells and sepiolite as rheology modifiers in 3D concrete printing for the first time. Additionally, it presents a novel dog-bone-shaped structure test for assessing interlayer bond performance.