Interfacial Fracture Research Articles

Measurement of the interfacial energy release rate (ERR) and cohesive law parameters of polyvinyl butyral laminated glass using a novel beam-type test specimen

The polyvinyl butyral (PVB) laminated glass (LG) structures are widely used in architectural and automotive sectors. Determination of the interfacial fracture energy (i.e. G) between the PVB layer and glass is one of the most vital procedures for ensuring the structural safety and fracture resistance of these kinds of components. The present study investigates the adhesion characteristics between glass and PVB interface in a LG composite structure. A new simple test fixture is introduced to measure the mixed-mode fracture energy from pure mode I (i.e. GI) to pure mode II (i.e. GII). By making use of the concept of Equivalent material Concept (EMC), linear elastic fracture mechanics (LEFM) formulations together with finite element (FE) analysis can be used to compute the compliance parameter of the system and pure modes I/II fracture energies. Besides, the interaction of cohesive forces between the PVB layer and glass are simulated by using a FE method based on a bi-linear cohesive zone model (CZM) technique. In this regard, the cohesive law parameters are computed for mode I and mode II in an iterative process. Then, the obtained pure mode cohesive law parameters are utilized to predict the mixed-mode load–displacement diagrams. The obtained results demonstrate the satisfactory accuracy of the cohesive law parameters and fracture energies in predicting the mixed-mode loading results across four different loading rates (i.e. LR = 2, 5, 10, and 15 mm/min).

Understanding the mechanisms behind ultrasonic vibration in resistance spot welding of aluminum and steel

An ultrasonic-assisted resistance spot welding process, which can improve the quality of aluminum/steel spot-welded joints, has been developed. However, the mechanism of the thermal-electrical-mechanical behavior caused by the ultrasonic longitudinal vibration to welding process has not been clarified. In this study, the role and impact mechanisms of ultrasonic longitudinal vibration during the welding process to form joints were confirmed by combining the microstructural characterization of the formed joints with the signal analysis of the process, as well as the analysis of the independent finite element numerical calculation results. Additionally, the interface metallurgical reaction behavior, welding defects, fracture behavior, and joint strength characteristics of ultrasonic-assisted aluminum/steel resistance spot welding joints were comprehensively analyzed, and the results indicated that the sizes of the aluminum/steel nuggets decreased. It could be attributed to the competition among multiple ultrasonic effects. Specifically, ultrasonic vibration decreased the contact resistance between the aluminum/steel sheets, whereas the acoustic cavitation and acoustic streaming effects increased the electrical conductivity of molten steel and thermal conductivity of molten aluminum, respectively. Moreover, ultrasonic vibration promoted the radial creep of molten and near-molten aluminum, which expanded in the effective bonding area between the two workpieces. Furthermore, ultrasonic vibration effectively reduced the thickness of the intermetallic compound layer (<3.0 µm), concurrently inhibited the formation of interfacial welding defects. Finally, the peak tensile-shear load of aluminum/steel joints is significantly increased under multiple ultrasonic optimization mechanisms.

Characterization of the interfacial structure and fracture behavior of in situ synthesized ceramics to reinforce Ni-based composite coatings

This work used the in-situ synthesis of molten-state nitride ceramic phase-reinforced Ni-based alloy coatings, aiming to improve the phase-interface bonding through the interdependent co-solidification between molten droplets. The XRD was used to analyze the physical phases of the composite coatings. The microstructure and phase-interface structure were characterized in detail by combining SEM, TEM, HRTEM, FFT, and SAED techniques. Microhardness tester and microforce microhardness tester were employed to measure the surface hardness and elastic modulus of the composite coatings. The fracture behavior of the composite coatings was characterized by observing the fracture morphology of the coatings using SEM combined with the EDS technique. It was found that the formation mechanisms of interfacial misfit dislocation assistance, lattice distortion, aggregation of stacking faults, and specific growth orientation between the γ-Ni matrix phase and each ceramic phase in NiCrBSi-TiCrN composite coatings improved the lattice matching between the two-phase interface, which resulted in the formation of atomically corresponding coherent lattice relations and stepped interfacial semi-coherent lattice relations, and enhanced the degree of phase-interface bonding. On this basis, the composite coatings with high Cr content further inhibited the expansion of interphase penetration cracks due to the existence of Cr-rich zones at the phase interface, thus exhibiting high fracture toughness. This work provides new opinions on the improvement of phase-interface bonding and composition design of Ni-based composite coatings.

Study of high temperature mechanical properties and damage behavior of Ni-YSZ anode/SrO–MgO–SiO2 glass-ceramic sealant/430 s.s. interconnect system in solid oxide fuel cells (SOFC)

In the sealing system of Ni-YSZ anode/SrO–MgO–SiO2 glass-ceramic sealant/430 s s. interconnect, the phase transformation and mechanical properties of interfaces are studied after operating 0 h, 100 h, and 1800 h at 750 °C. The results show that the interface fracture appears in the glass/anode and glass/interconnect interfaces after operating at 1800 h. The interface mechanical parameters within different operation times are collected to investigate the effects of crystallization, penetration, and high temperature mechanical properties on the interlayer stress and structure damage. The Sr2MgSi2O7 crystal phase increases the glass modulus from 104.5 GPa to 129.8 GPa with a runtime from 0 h to 1800 h. The modulus of the Ni-YSZ interface also increases from 82.4 GPa to 128.3 GPa with the glass penetration process. The 430 s s. modulus is reduced by 13 % at 750 °C after 1800 h to reach 191.1 GPa. The established anode/glass/interconnect interlayer stress model accurately calculates the compressive stress at the glass/anode side interface and glass/interconnect side interface, with values reaching −755.2 MPa and −587.1 MPa, respectively. The crystallization zone of the SrO–MgO–SiO2 glass-side interface near Ni-YSZ and 430 s s. become the stress damage sensitive zones and break under interlayer stress.

Bioinspired soft-hard interfaces fabricated by multi-material additive manufacturing: A fracture mechanics investigation using essential work of fracture

This study employs the Essential Work of Fracture (EWF) concept to evaluate the interfacial fracture toughness of bioinspired interfaces between soft and hard polymer phases. The experimental framework utilizes a model material system with Polylactic Acid (PLA) as the hard phase and Thermoplastic Polyurethane (TPU) as the soft phase. Employing the Fused Filament Fabrication (FFF) technique, bioinspired sutural interfaces are created, characterized by interpenetrating soft and hard protrusions. The modulation of a critical parameter in the FFF process enables the variation of interpenetration length of protrusions at the interface, thereby achieving a spectrum of interfacial strength and toughness. The determination of essential work of fracture from double edge notch tension samples, with varied ligament sizes, allows for the specific EWF measurement. This specific EWF is found to align with the initiation value of plane strain interfacial fracture toughness obtained through the Double Cantilever Beam (DCB) test. Therefore, the proposed approach asserts the elimination of the need for complex interfacial fracture tests, such as DCB. A noteworthy discovery is the establishment of a correlation between specific plastic energy dissipation and protrusion length. This correlation suggests an increased plastic dissipation with longer protrusions within the investigated bioinspired interface. Due to this heightened plastic energy dissipation, the shape of the interfacial nominal stress-displacement curves demonstrates substantial dependence on interface morphology, shifting from a triangular to a trapezoidal shape as protrusion length increases. These findings offer valuable insights into the mechanics of bioinspired interfaces, presenting a more efficient and nuanced approach to characterizing their fracture properties.

Non-oscillatory fracture mode partition for interface crack under mixed-mode loading

The oscillatory crack-tip field in the classical interface fracture mechanics solution often leads to complications in identifying the mode mixity in bimaterial interface fracture problems. In this paper, a non-singular series solution for the continuum problem of a crack on the cohesive-spring interface under mixed-mode loading is presented and compared to the classical oscillatory solution. A Gaussian process regression model was also developed to enable quick evaluation of the phase angle for interface delamination characterization by using mixed-mode bending fracture test.

Revealing the grain boundary effect on interfacial adhesion in polycrystal Fe/Ni interfaces by using a multi-scale CZM-CPFEM approach

In layered structure, interface plays a significant role in property improvement, whereas its multiple factors at various length scales restricted further understanding. Previous research found a novel grain boundary (GB)-interface interaction: crack initiation locally occurred at the junctions between pre-existing GBs and interface. This leads to decreased interfacial strength. To clarify the mechanisms of such GB-interface interaction, the present study proposed a multi-scale cohesive zone model-crystal plasticity finite element method (CZM-CPFEM) model to investigate the effect of pre-existing GB on intrinsic bonding strength at atomic scale and interfacial stress distribution at micro scale, respectively. At atomic scale, interfacial fracture criteria were modelled according to Molecular Dynamics (MD)-based traction-separation relationships. The accuracy of CZMs was improved by considering both isothermal holding and tilting configuration effects. At micro scale, a practical interfacial microstructure was used to construct CPFEM models. Tensile simulations showed that the local stress concentration occurred at junctions, attributed to the anisotropic plastic deformation behaviours across the GB. On the other hand, weak bonding adhesion at the junction only affects the local crack initiation strength, showing insignificant impacts on the overall interfacial fracture behaviour.

Novel, high throughput interface fracture testing method for thermal spray coatings: The modified cantilever bend technique

To measure the interfacial fracture toughness of ceramic/metal interfaces such as thermal spray coatings, a novel modified cantilever beam bending method is proposed. Finite element simulations are used to determine the energy release rate and phase angle for an interfacial crack in a bi-layered cantilever for varying modulus, thickness and beam aspect ratios. A high-throughput experimental procedure for the new test geometry is presented to extract a large number of measurements of interface fracture energy from the same sample, using digital image correlation. Interfacial fracture energies GC, determined using this method are compared for thermal spray coatings of Alumina and YSZ on steel substrates. GC of these coating-substrate combinations follow the same trend as measured from four-point bending or modified clamped beam bend techniques. Advantages and limitations of the technique in comparison to other methods in practice are discussed.

Deformation and fracture of SiCp/Al composites under complex loading conditions: A simulation study

An accurate depiction of the deformation and fracture mechanisms of metal matrix composites is the key to their rational structure and property design. In the present work, the Advanced Guerson Tvergaard Needleman (AGTN) constitutive model is firstly combined with an algorithm to reconstruct realistic 3D microstructures within the finite-element framework. We employ this model to probe the elastoplastic response and fracture behaviors of aluminum matrix composites with different volume fractions of reinforcing particles (7, 14, and 21 %) and under various loading conditions (tension, compression and shear). Real microstructures are referred to reconstruct the three-dimensional model of the composites. The AGTN constitutive model is integrated with the micromechanical damage model, which is capable of independently describing the constitutive behavior of various components, including the elastoplastic damage of the metal matrix, particle-enhanced elastic-brittle failure, and the interfacial traction separation. By using the conventional SiCp/Al composite system as a model material, we examine the stress state of the matrix and fracture mechanisms under different loading conditions by using triaxiality, Lode angle and statistical analysis. In general, the damage of SiCp/Al composites can be attributed to interfacial debonding and particle fracture, whereas the latter dominates when the volume fraction of SiCp is high. Furthermore, the critical volume fraction for the transition of damage mechanisms is found to be largely dependent on the loading conditions. Our work provides a comprehensive understanding of particle-reinforced aluminum matrix composite under in-service conditions.

Investigation on the joining process and strength of laser circle welding between Al5052 and CFRP dissimilar materials

Laser welding is an effective approach to joining metal and composite. In the present research, laser circle welding was proposed to join the Al5052 sheet and PA6-CFRP as the first try. A process window was suggested according to the welding results and joint appearance. Single lap shear test was employed to evaluate the mechanical performance of welded joints under different welding conditions. The cross-section and fracture surface were subjected to multi-scale characterizations to subdivide the joining zone and understand the joining process. The result showed that 10 sets in 18 groups of welding parameters can achieve successful bonding. The welding results can be classified into four categories: non-connected, aging-failing, effective-joining and burn-through. The joining zone of laser circle welding was divided into three subregions. The adhesive zone (AZ) presented an interfacial fracture while the local failing passed through plastics basement in cohesive (CZ). The overheating of CFRP generated decomposed zone (DZ). The signal peak of O-C=O bond disappeared in the entire joining zone on CFRP sheet and the intensity of carbide was significant in DZ. The laser circle welded joint presented brittle and ductile fracture modes, which were related to the joining zone component. The joining strength can reach about 656 ± 22 N, 2135 ± 331 N and 3223 ± 257 N under one-circle, double-circle and three-circle scanning, respectively. Increased scanning numbers can decrease the required laser power and improve joining strength by extending heating time, while it also increased the risk of burn-through.

Spider silk-inspired heterogeneous interphase featuring hybrid interaction for simultaneously improving the interfacial strength and fracture toughness between carbon fiber and epoxy by regulating hydrogen bond density

Designing advanced fiber-reinforced polymer composites through biological inspiration proved to be a crucial strategy for overcoming limitations in simultaneously enhancing the strength and toughness of composites. To achieve simultaneous improvement in the interfacial strength and toughness between carbon fiber (CF) and epoxy, a spider silk-inspired interphase featuring hybrid interaction was constructed by introducing hyperbranched polyamide-amine (HPAA) and graphene oxide (GO) onto the surface of CF. The results suggested that manipulating the feed ratio to adjust the branching degree of HPAA allowed for the attainment of various hydrogen bond densities. The fiber surface with high hydrogen bond density provided more hydrogen bond interaction sites to promote the deposition of GO. Benefitting from the ameliorative interfacial adhesion force, surface energy and interface thickness, impressive improvements of 94.5 % and 110.0 % in respective interfacial strength and fracture toughness over those of untreated CF/EP composites were achieved for functionalized CF/EP composites. The enhancement mechanism of interfacial performance was attributed to the formation of a “nano-fishnet” structure, which improved the stress transformation efficiency and consumption of external energy absorbed by hydrogen bonds. The method of regulating the branching degree of hyperbranched polymers and hydrogen bond density has opened an advanced way for surface modification of high-performance fibers.

Mixed experimental-numerical method for quantitative measurement of mode II fibre/matrix interface debonding and comparison of fibre sizings in single short fibre composites

In short fibre composites, debonding cracks usually initiate from fibre tips and their growth is governed by the properties of the fibre/matrix interface. These properties are ideally acquired from a model test similar to the real composite, while excluding the effects of fibre fractures and the induced debonding interactions. Therefore, in this study, debonding growth was examined in detail, using novel single short fibre specimens, which were fabricated using a new methodology. These experiments were further complemented with a continuous fibre case study, where the established single fibre fragmentation specimens were evaluated. The progression of debonding and pull-out damages versus remote stress was studied for two fibre sizings utilizing real-time in-situ polarized light microscopy. A finite element model was built to obtain the fibre/matrix interfacial fracture toughness considering thermal residual stresses, friction and matrix plasticity, and a very good correlation was obtained between the model and the experiments.

Investigation on the interface bonding and reinforcement mechanism of nano Ti/AZ31 magnesium matrix composites

In this study, nano Ti/AZ31 composites were successfully prepared by powder metallurgy method, and the strength and plasticity of the composites were improved in both directions. The SEM shows that the Ti particles were evenly distributed at the grain boundary in the sintered composite, and the Ti particles pin the grain boundary to make the grain of the composite significantly refined. EBSD shows that the addition of nano Ti particles significantly reduces the texture strength of the composite and increases the starting probability of the slip system. TEM shows that nano Ti and AZ31 matrix formed stable Al3Ti and MgO phases at the interface, and shows a strong coherent relationship. The nanoindentation test shows that the Ti/AZ31 interface of the composite was stable, the interface bonding energy and interface fracture toughness were gradiently distributed, and the bonding energy and fracture toughness of the interface bonding area were better than those of the matrix. Tensile test shows that the 1.5 wt%Ti/AZ31 composite obtained the best comprehensive mechanical properties with yield strength, ultimate tensile strength and elongation of 143 MPa, 243 MPa and 11.5%, respectively, obviously higher than those of AZ31 alloys. The increased strength was mainly due to the grain refinement and strengthening at grain boundaries. The improved ductility was the result of weakened texture, increase of slip system start-up probability and strong interfacial bonding between Ti particles and AZ31 matrix.

High strength diffusion bonding of Ti2AlNb to GH4169 with (TiZrHfNb)95Al5 high entropy interlayer

A high entropy interlayer (TiZrHfNb)95Al5 was designed for vacuum diffusion bonding of Ti2AlNb to GH4169. The influence of bonding temperature on the interfacial microstructure morphology, mechanical properties and fracture behaviour of the resultant joints was investigated. The evolution of microstructure and fracture mechanism were revealed. The typical interface microstructure of Ti2AlNb/B2/Solid solution/(Ti, Zr, Hf)2(Ni, Nb)+(Ti, Zr, Hf)(Ni, Nb)+(Ti, Zr, Hf)(Ni, Nb)2+Solid solution/(Ti, Zr, Hf)(Ni, Nb)+(Cr, Ni, Fe)ss/(Cr, Ni, Fe)ss/Cr-rich(Cr, Ni, Fe)ss/Ni-rich(Cr, Ni, Fe)ss/GH4169 was formed. As the bonding temperature increased, the thickness of interfacial reaction layer gradually increased, and the shear strength gradually increased until 980 °C, then decreased sharply. The highest shear strength reached 376 MPa at 980 °C for 90 min. The highest microhardness region of 11.79 GPa existed on the GH4169 side, which was mainly composed of (Ti, Zr, Hf)(Ni, Nb) and (Cr, Ni, Fe)ss phases. Meanwhile, the elastic modulus dramatically changed interface formed near this region. The fracture surface morphology indicated typical brittle fracture characteristics such as cleavage steps, transgranular fracture and intergranular fracture. According to the fracture analyses, major cracks initiated in the (Ti, Zr, Hf)(Ni, Nb) phase+(Ti, Zr, Hf)2(Ni, Nb) phase and gradually extended to the (Cr, Ni, Fe)ss phase. Thus, the major crack emerged region was located at the elastic modulus dramatically changed interface.

Microstructure-chemomechanics relations of polycrystalline cathodes in solid-state batteries

Lithium-nickel-manganese-cobalt-oxides (NMC) embedded in solid-electrolytes are being extensively applied as composite cathodes to match the high energy density of metallic anodes. During charge/discharge, the cathode composite often degrades through the evolution of micro-cracks within the grains, along the grain boundaries, and delamination at the particle-electrolyte interface. Experimental evidence has shown that regulating the morphology of grains and their crystallographic orientations is an effective way to relieve the volume-expansion-induced stresses and cracks, consequently stabilizing the electrochemical performance of the electrode. However, the interplay among the crystal orientation, grain morphology, and chemo-mechanical behavior has not been holistically studied. In that context, a thermodynamically consistent computational framework is developed to understand the role of microstructural modulation on the chemo-mechanical interactions of a polycrystalline NMC secondary particle embedded in a sulfide-based solid electrolyte. A phase-field fracture variable is employed to consider the initiation and propagation of cracks. A set of diffused phase-field parameters is adopted to define the transition of chemo-mechanical properties between the grains, grain boundaries, electrolyte, and particle-electrolyte interfaces. This modeling framework is implemented in the open-source finite element package MOOSE to solve three state variables: concentration, displacement, and phase-field damage parameter. A systematic parametric study is performed to explore the effects of aspect ratio, the crystal orientation of grains, and the interfacial fracture energy through the chemo-mechanical analysis of the composite electrode. The findings of this study offer predictive insights for designing solid-state batteries that provide stable performance with reduced fracture evolution.

Improvement of microstructure and mechanical properties of laser welded Al-Si coated 22MnB5 steel joints by austenitic element copper

In this experiment, the effects of different copper foil thicknesses on the morphology, structure, and mechanical properties of laser lap welded 22MnB5 steel joints were studied. The aim was to reduce the damage of Al-Si coating and increase the mechanical properties of welded joints. As the thickness of copper foil increases from 0 to 100μm, there was a gradual decrease in the presence of δ-ferrite in the fusion zone (FZ) and fusion boundary (FB), while the copper-rich content of lath martensite (LM) gradually increased. The reason was that Cu is an austenite element which can expand the γ phase area and play a stabilizing and strengthening role. The result of JmatPro software can support it. It found peritectic reaction (L+δ→γ) range expanded from 1414 to 1422°C to 1436–1453°C which led to more γ phases formed during the solid-state phase transition (δ→γ) at high temperature. Based on this phenomenon, as the copper foil increased (0–100μm), the joint tensile strength increased from 361 MPa to 706 MPa. However, after adding too much copper foil (200μm), the microstructure of FZ varied to a copper-rich phase (ε-Cu) with low hardness and brittleness which adhered to the martensite grain boundaries and reduced the bonding force of the crystal boundaries, so the the mechanical properties of the weld joint seriously reduced (232 MPa). When the copper foil was thin or non-existent (0–30μm), there was still more delta ferrite in FB (low strength and brittle), and the fracture type of the joint mainly appeared as a cleavage fracture. When adding 100μm copper foil, the fracture expressed ductile fracture due to the interfacial fracture due to the lack of δ-ferrite in FB. If the thickness of Cu increased to 200μm, the fracture changed back to FB which expressed a quasi-cleavage fracture.

A 3D multi-phase-field model for orientation-dependent complex crack interaction in fiber-reinforced composite laminates

We formulate a 3D multi-phase field model to simulate bulk and interfacial fracture in fiber-reinforced composites. The purpose of this study is to predict the complex crack interaction between the interlaminar and intralaminar fracture in FRPCs. For that, the discrete crack and the sharp interface are both smeared using the phase-field approach. A second-order anisotropic tensor is incorporated in the elastic as well as the fracture surface energy to promote direction-dependent crack growth. The interface constitutive behavior is represented by the uncoupled 3D traction–separation laws—in exponential and bi-linear form. The proposed model captures the complicated failure phenomena in FRPCs such as matrix damage, interfacial delamination, and their interactions for different configurations of lamina with different fiber orientations and fracture energies. This model’s capability is further illustrated to study the three common modes of fracture i.e. modes I, II, and III, in 3D FRPC laminates where the crack impinges on the interface. Finally, the obtained framework is validated by two benchmark problems including the mode I and mode II delamination test, and is compared against experimental data reported in the literature.

Estimating the macro strength of rock based on the determined mechanical properties of grains and grain-to-grain interfaces

Obtaining complete rock cores is exceptionally challenging in certain extreme environments, such as deep earth and deep space; consequently, it is difficult to obtain the macro strengths of rock, which are the key indexes for engineering design, via standard rock mechanical tests. This research indicates that by determining and leveraging the mechanical properties of grains and grain-to-grain interfaces, the rock macro strength can be effectively estimated. Nanoindentation tests were first conducted to determine the elastic modulus of the mineral grains and their interfaces. Subsequently, symmetrical and anti-symmetrical four-point bending tests were executed to establish the statistical law governing interfacial tensile and shear fracture toughnesses. Furthermore, by employing the Dugdale–Barenblatt model and considering the oblique angular distribution of interfacial cracks, the corresponding tensile strength, shear strength, and friction parameter were derived. These meso‑mechanical parameters were then inputted into the 3D Finite-Discrete Element Method to estimate rock macro strength. And the numerical results were then compared with the results of standard uniaxial compression, direct tension, Brazilian splitting, and direct shear tests. The consistency observed between the predictions and experimental results attests to the validity of the proposed method.

Interfacial failure behavior of Thermal Barrier Coatings (TBCs) at high temperatures: An in-situ indentation study based on X-ray imaging

Interfacial failure behavior is a major concern during the service of thermal barrier coatings (TBCs). Quantitative study on interfacial failure behavior of TBCs at high temperatures remains a great challenge. In this study, an in-situ high-temperature cross-sectional indentation (HCSI) method based on X-ray imaging was developed. The out-of-plane displacement of TBCs was measured by in-situ digital radiography (DR) technology. The morphology of the interfacial crack was characterized by an in-situ computer tomography technology. It was found that the interfacial fracture region tended to be semi-elliptical shaped. The strain energy during HCSI was quantified and analyzed by finite element analysis (FEA). The composite stress intensity factor (SIF) and the mixed modal angles at high temperatures were obtained by analyzing the stress field at the crack tip. Interfacial toughness of TBCs at RT, 400 °C, and 800 °C were obtained. The interfacial toughness changes little ranging from RT to 400 °C, while it sharply decreases ranging from 400 °C to 800 °C. A prediction model for the evolution of interfacial toughness with temperature was obtained. The competition mechanism of interfacial cracks at different temperatures was discovered. The relationship between the change in interfacial toughness and the failure mode evolution was discussed.

“Like binding a book”: Interfacial improvement of pre-melted ultrahigh molecular weight polyethylene by pulse vibration molding

Ultrahigh molecular weight polyethylene (UHMWPE) is widely used in industrial, military, and civilian applications owing to its excellent properties. However, the high entanglement degree of UHMWPE melt leads to great difficulties in diffusion and crystallization, which causes poor interfacial strength and mechanical properties of pre-melted UHMWPE, restricting its high-quality processing and high-value recycling. To this end, we propose a rapid interface stitching technology with a pulsed vibration force driving free volume homogenization and chain segment orientation. For the first time, pulse vibration molding (PVM) is applied for the hot-pressing of pre-melted UHMWPE, successfully realizing the interface stitching and product strengthening. Compared with those of the convention molding (CM) samples at 180 °C, the interfacial adhesive fracture toughness of the adhesive samples processed using PVM is increased by 105.9 % and the work of tension of the recycled samples processed using PVM is also increased by 49.09 %, respectively. The fracture strength of the PVM recycled samples at 180 °C reaches 91.77 % of that of the pure samples and the yield strength is also higher, which significantly enhances the recycling of UHMWPE. The characterization results of the interfacial molecular chain entanglement and crystallization show that PVM strengthens the molecular chain diffusion and induces crystallization by promoting the orientation of chain segments, especially at the interface. Consequently, we believe that the proposed technology can play a significant role in the UHMWPE processing methods that involve surface healing.