Inhomogeneous Microstructure Research Articles

Numerical simulation and experimental validation of microstructure evolution during the upsetting process of a large size martensitic stainless steel forging

The microstructure evolution, plastic deformation, and damage severity during the open die hot forging of a martensitic stainless steel were investigated using finite element (FE) simulation. A microstructure evolution model was developed and combined with a visco-elastoplastic model to predict the strain, the strain rate, and the temperature distribution, as well as the volume fraction and the size of dynamically recrystallized grains over the entire volume of an industrial size forging. The propensity to damage during hot forging was also evaluated using the Cockcroft & Latham model. The three models were implemented in the FE code and the results analyzed in terms of microstructure inhomogeneity and stress levels in different regions of the forging. A good agreement was obtained between the predicted and the experimental results, demonstrating that the simulation provided a realistic representation of the forging process at the industrial scale.

Effects of homogenization and deep cryogenic treatments on microstructure and mechanical property of D2 tool steel fabricated by laser direct energy deposition

The integration of laser direct energy deposition (L-DED) for manufacturing high-hardness D2 tool steel components presents a promising avenue for addressing the increasing complexity of product geometries demanded by modern industry. However, the inherent variability in microstructure and mechanical properties induced by L-DED across the build height necessitates the employment of post-processing techniques to achieve material homogeneity. This study explores the synergistic application of homogenization and deep cryogenic treatment (DCT) as a novel post-processing strategy aimed at mitigating microstructural inhomogeneities and enhancing the mechanical properties of L-DED-fabricated D2 tool steel. Initial analysis of the as-built samples revealed a microstructure characterized by a fine network of eutectic carbides enveloping an FCC matrix, which imposed constraints on martensite transformation during DCT. Homogenization was found to effectively alleviate these constraints, promoting compositional and microstructural uniformity and enabling a more consistent transformation to martensite across the samples upon subsequent DCT. The strategic combination of homogenization and DCT resulted in achieving uniformly distributed high hardness levels exceeding 750 HV throughout the entire sample, regardless of their initial positions within the build. This study demonstrates the potential of combining homogenization with DCT as an effective approach to enhance the structural integrity and mechanical performance of L-DED-fabricated D2 tool steel, offering valuable insights for the development of advanced manufacturing processes for alloyed materials.

Studies of electrical resistivity and magnetic properties of CuFe and CuNiFe films prepared by magnetron sputtering

The Cu-Fe binary alloys exhibit severe elemental segregation, resulting in an inhomogeneous microstructure, which leads to differences in microregion magnetic properties, thus affecting their application. Employing magnetron sputtering to produce films is advantageous for achieving a consistent dispersion of Fe within the Cu matrix. Furthermore, the addition of Ni will result in a more uniform distribution of Fe and facilitate the formation of the ferromagnetic Ni3Fe phase. In this study, Cu100−xFex and Cu100−x(Ni3/4Fe1/4)x series films were prepared by magnetron sputtering technique. The magnetic properties of films are closely related to their ferromagnetic element content. An increase in the content of ferromagnetic elements leads to an improvement in the saturation magnetization (MS) strength and a decrease in the coercivity (HC). The formation of Fe-Fe pairs is more favorable for magnetic properties compared to Ni-Fe pairs. Meanwhile, by comparing with bulk alloys, the distribution of the magnetic elements severely affects the magnetic properties. Moreover, the resistivity of Cu100−xFex films (20.3–96.7 μΩ cm) is much higher than that of Cu100−x(Ni3/4Fe1/4)x films (15.6–60.6 μΩ cm), which depends on the magnetic properties. This study systematically analyzes the effect of the content and distribution of magnetic elements on magnetic and electrical properties.

Quantification of microscale factors for fatigue failure in NiTi shape memory alloys

Fatigue behavior is intrinsically linked to microstructural alterations induced by cyclic loading. However, the quantification of microstructural defects associated with fatigue damage of NiTi shape memory alloys (SMAs) is lacking, which hinders the development of a physically based fatigue criterion. To this end, a multi-scale experimental analysis was conducted on cyclically deformed NiTi SMAs, which evidenced a strong correlation between microstructural inhomogeneity and localized deformation behavior. The microstructural change associated with fatigue was quantified in terms of stored strain–energy, with the highest values observed in the regions where fatigue cracks initiate. Consequently, stored energy is deemed as an effective fatigue indicator, offering valuable insights for future work in the design and optimization of SMAs’ structures against fatigue.

Effect of inhomogeneous microstructures on stress corrosion cracking sensitivity of 2050-T84 Al-Li alloy thick plate

Inhomogeneous microstructures in the thickness direction and stress corrosion cracking of 2050-T84 Al-Li alloy thick plate was investigated. The quarter layer of alloy thick plate exhibited the highest stress corrosion cracking sensitivity, which was related to AlCuMnFe IMPs, subgrains, orientation, T1 phase and dislocation density. In the quarter layer, the obstruction of subgrains to deformation bands resulted in significant stress concentration. Cracks originated from corrosion pits caused by AlCuMnFe IMPs around subgrains. The dealloying corrosion of T1 phase and the presence of Goss texture increased the brittleness of the alloy, further accelerating the stress corrosion cracking of the quarter layer.

Elucidating the challenges in the development and deployment of refractory complex concentrated alloys for additive manufacturing

The increasing demand for advanced materials with load-bearing capabilities in extremely high-temperature environments has brought considerable attention to the design and fabrication of novel refractory complex concentrated alloys. Despite the notable progress in design of customized alloys, there are still significant challenges regarding their processing and fabrication, highly limiting their exploitation. In this study, model non-equiatomic Nb-Ta based refractory complex concentrated alloys were created as potential materials with improved high-temperature stability and performance for space propulsion applications. Gas atomization was used for producing spherical pre-alloyed powders. Two different additive manufacturing techniques, i.e., laser powder bed fusion and cold spray were used to explore the manufacturing complexities of this novel alloy. The results highlight the importance of powder’s features on its processability by laser powder bed fusion and cold spray. High interstitial content, inhomogeneous microstructures, fractured and hollow particles, and the presence of microsegregation, led to embrittlement, and in case of cold spray, the wide particle size range of the feedstock resulted in undesired flowability, adversely affecting the processibility of the developed material. The obtained results provide valuable insights and recommendation for improving design, preparation, and fabrication of custom-designed refractory alloys for additive manufacturing.

In vitro and in vivo studies of a biodegradable Zn-4Ag-0.1Sc alloy with high strength-elongation product, cytocompatibility, osteogenic differentiation, and anti-infection properties for guided bone-regeneration membrane applications

Zinc-silver (Zn-Ag) alloys are generally promising guided bone-regeneration membrane (GBRM) materials due to their moderate degradability, osteogenic differentiation, and antibacterial properties. However, Zn-Ag alloys often display microstructural inhomogeneity and mechanical instability due to the formation of coarse Ag-rich second phases. In this study, Zn-4Ag and Zn-4Ag-0.1Sc (denoted ZA and ZAS, respectively) were comparatively investigated, and the ZAS exhibited a suitable degradation rate, high strength-elongation product, cytocompatibility, antibacterial capacity, and in vitro and in vivo osteogenic properties, making it highly appropriate for GBRM applications. Among all the as-cast and hot-rolled (HR) samples, the HR ZAS had the highest ultimate tensile strength of ∼260.5 MPa, tensile yield strength of ∼202.0 MPa, and elongation of ∼72.7%. The HR ZAS also exhibited a higher degradation rate of ∼36.5 µm/a in Hanks’ solution than those of the HR ZA, while its diluted extract was more cytocompatible and capable of osteogenic differentiation toward both MG-63 and MC3T3-E1 cells. The HR ZAS showed an exceptionally effective antibacterial ability against S. aureus in both in vitro antibacterial testing and in vivo subcutaneous infection models. Further, the HR ZAS demonstrated better osteogenic and histocompatibility properties than those of pure Zn in a rat skull defect model.

Crystal plasticity quantification of anisotropic tensile and fatigue properties in laser powder bed fused Inconel 718 superalloy

The high thermal gradients during the laser powder bed fusion (LPBF) process induce an inhomogeneous microstructure with anisotropic mechanical properties. This study developed a dislocation-based strain-gradient crystal plasticity finite element (CPFE) model to reveal the microstructure-based deformation mechanisms and quantify their strengthening contributions to the mechanical property anisotropy of LPBF-ed Inconel 718 (IN718) superalloy. The analyzed microstructural attributes included 1- crystallographic orientations/misorientations, 2- solid solutions (SS), 3- grain size and morphologies, and 4- dislocation dynamics, such as statistically stored dislocations (SSDs) and geometrically necessary dislocations (GNDs). The investigated mechanical properties contained tensile strength, fatigue resistance, fracture mechanisms, and their anisotropy under loading towards building (BD) and transverse (TD) directions. The experimentally obtained microstructural features of the as-LPBF-ed IN718 were synthesized into the crystal plasticity representative volume elements (CPRVE) to model the deformation behavior using a user-defined material subroutine (UMAT) in the ABAQUS solver. The energy-based fatigue indicator parameter (FIP) captured the fatigue properties and failure mechanisms. The main slip-strengthening contributions stemmed from SSDs, grain size, SS, and GNDs. in TD. The corresponding order in BD was SSDs, SS, GNDs, and grain size because the grain dimensions were larger in BD than in TD. The grain-size effect had the highest contribution to the tensile property anisotropy, followed by SSDs, GNDs, and SS. Aside from their strengthening effects, crystal texture and grain size induced mechanical property heterogeneity and fatigue sensitivity at grain boundaries, reducing their contributions to fatigue strength relative to tensile. In contrast to the previous findings, local accumulations of SSDs and GNDs at softer sides of grain boundaries during cyclic loading reduced the strength heterogeneity in these areas, improving fatigue properties. The highest slip-strengthening effect for fatigue resistance and anisotropy was under SSDs, followed by GNDs, SS, and grain size.

Microstructure size and packing of fracture surface on the nonlinear breakage mechanical response of different marbles under cyclic loading

The microstructural properties of fracture surfaces are a remarkable reflection of the nonlinear mechanical properties of rocks, which have not been thoroughly evaluated to date. In order to understand the contributions of microstructure size and packing to the nonlinear mechanical response, both micro- (field emission scanning electron microscopy (SEM) experiments on failure specimen section) and macro-scale (unequal amplitude cycle experiment) tests were carried out on different marbles. The size and arrangement properties of microstructures on the fracture surface were determined using digital image recognition technology based on micro-scale experiments. Remarkable differences were observed among different types of marble in terms of breakage evolution, fracture combining form, and nonlinear evolution of energy. The micro-deformation of marbles is characterized by the deformation distribution and microstructure inhomogeneity in strong deformation zones of failure. The microstructures of brittle-ruptured marbles exhibit mechanical fragmentation and fracture of mineral grains. The ductile deformation of marble is characterized by the presence of solid flow traces within the mineral crystals, as well as the loose arrangement of mineral crystal grains in the strongly deformed zones. The constitutive model for marble samples with fine mineral crystals can be derived by nonlinearly separating the Helmholtz free energy during the breakage process and defining the relationship between breakage force and dissipated energy in the absence of residual strength after fracture. The obtained nonlinear breakage constitutive equation is in good agreement with the experimental results. These findings may provide basis and inspiration for engineering construction and geological disaster prevention.

Microstructure amelioration and strength-ductility improvement of WAAM-LDM hybrid additive manufacturing Ti-6Al-4V alloy by solution treatment and aging

WAAM-LDM hybrid additive manufacturing can achieve high efficiency and high precision preparation of Ti-6Al-4V alloy. However, the inhomogeneous microstructure of WAAM-LDMed Ti-6Al-4V samples results in overall poor tensile properties. Therefore, this paper attempts to ameliorate the inhomogeneous microstructure of the hybrid sample by STA, and simultaneously improve the strength and plasticity. The results showed that the WAAM zone and HAZ were composed of α colonies, the RZ and LDM zone were distributed with fine basketweave structure of the AD samples. With the introduction of STA, the microstructure of each zone of the hybrid sample changes and transformed into a ‘dual-phase’ structure with bi-modal αp and βt. With the increase of aging temperature, the volume fraction of βt increased and the volume fraction of αp phase decreased, accompanied by the formation of bulk α phase and the coarsening of αs phase. It is worth noting that the strength of WAAM zone was obviously improved by STA, and the fracture positions of the STA samples were randomly distributed in the WAAM and LDM zones. Additionally, with the aging temperature increased, the strength of WAAM-LDMed samples was weakened, and the ductility was improved because the coarsened bulk α played a role of coordinating deformation in the tensile process. The excellent strength and ductility (UTS = 976 MPa, YS = 876 MPa, EL = 13.57%) of WAAM-LDMed samples was achieved at aging temperature 750 °C, compared with the AD samples (UTS = 860 MPa, YS = 767 MPa, EL = 12.5%). Finally, by optimizing the STA (940 °C/1 h/WQ + 750 °C/4 h/AC), the amelioration of the microstructure and the improvement of the strength-ductility of the hybrid samples were achieved.

Study of the microstructure evolution of alloy structural steel and inhomogeneity effect of the microscale pulsed currents during current-assisted plane strain compressions by modeling a novel cellular automata method

The current-assisted forming process is considered to be a novel process that utilizes the electroplasticity effect to reduce the deformation resistance of difficult-to-deform metals and to refine the grain size while improving the mechanical properties of the part. However, the lack of understanding of the mechanisms by which pulsed current affects grain refinement still makes it difficult to experimentally develop analytical or empirical models of the relationship between grain size, pulse current parameters, and deformation amount. It will seriously hinder the further development and application of the current-assisted forming process. To reveal the mechanism of grain refinement coupling with electroplasticity, a series of Electron Back Scattering Diffraction observation tests were carried out after current-assisted plane strain compressions. The results show that the grain orientation spread value of the pulse current condition is lower than that of the non-current condition, while the refined grain area percentage is higher than that of the non-current condition. Based on the microstructure observation results, a cellular automata model for grain refinement is proposed. This consists of a dislocation density evolution, sub-grains generation, grain fragmentation, and a grain orientation rotation algorithm. To study the electroplasticity of the grain refinement process, the cellular automata model is also embedded with a finite difference numerical algorithm for solving the microscopic current density distribution of the model. The cellular automata model simulation results show that the error of grain size accuracy of this cellular automata model under non-current and pulse current conditions is 10.48% and 8.55%, respectively. It shows that the model can accurately characterize the grain refinement behavior of the current-assisted plane strain compression. The simulation results reveal the deep mechanism of pulsed current promotion on grain refinement, i.e., an inhomogeneous microstructure leads to uneven distribution of pulse current density. The inhomogeneous current distribution will further increase the grain refinement rate in the coarse-grained regions, thus increasing the proportion of the refined grain regions in the microstructure and leading to a relatively more homogeneous microstructure under pulse current conditions. The cellular automata model accurately reveals the mechanism of electroplasticity on the grain refinement. The model will serve as a crucial theoretical reference in designing current-assisted forming process routes to ensure excellent microstructure and properties in manufactured parts. It will enhance the widespread utilization of current-assisted forming process.

Strong diffraction effects accompany the transmission of a laser beam through inhomogeneous plasma microstructures.

In the study we thoroughly analyze diffraction effects accompanying the laser beam transmission through inhomogeneous plasma microstructures and simulate their diffraction patterns at the object output and in the near field. For this we solve the scalar Helmholtz wave equationin the first Rytov approximation and compute the diffraction spreading of the transmitted beam in free space. Diffraction effects are found to arise within the beam passage through inhomogeneous plasma microstructures even in the simplest approximations of the laser beam interaction with plasma. These effects become strong in the near-field region and significantly distort the patterns of plasma formations, as well as facilitate the appearance of various optical artifacts in the plasma images. By performing numerical simulations, we characterize in detail the features of the visualization of plasma formations in the field of a coherent laser beam registered by a lens system. The calculations are in good agreement with the experimental data. The study can find broad applications in the processing of the laser images of plasma microstructures registered by lens systems in the presence of strong diffraction effects.

Preparation of W-Ni-Cu Alloy Powder by Hydrogen Reduction of Metal Oxides

The effect of powder processing on the microstructure and sinterability of the heavy alloy W-Ni-Cu was investigated. The heavy alloy powders were prepared by the ball milling and hydrogen reduction of metal oxide powders. As the milling time increased, the size of the powder mixture decreased and at 5 h of milling was found to be about 2.5 μm. Microstructural analysis revealed that the powder mixture was changed to W and NiCu alloys with an average particle size of about 200 nm after hydrogen reduction at 800°C for 2 h. The reduction kinetics of the oxide powder mixture was evaluated by the amount of peak shift with heating rates using TGA in a N<sub>2</sub>-10% H<sub>2</sub> atmosphere. The activation energy of the reduction reaction, calculated from the slope of the Kissinger plot, was measured to be 42.8 kJ/mol for CuO, 57.9 kJ/mol for NiO, and 50.1~112.6 for kJ/mol WO<sub>3</sub>. The relative densities of the heavy alloy sintered at 1100oC and 1200oC using oxide powder were 81.4% and 96.0%, while the specimen using metal powder as a raw material showed a relatively low value of 67% and an inhomogeneous microstructure. It was explained that the changes in sintered microstructure with different powder synthesis methods are mainly due to the powder characteristics, such as the size of the particles of the initial mixed powder.

The effect of inhomogeneous microstructures on strength and stress corrosion cracking of 7085 aluminum alloy thick plate

Inhomogeneous microstructures and alloy chemistry along the thickness direction can greatly affect the mechanical and corrosion properties of new generation 7xxx aluminum alloy thick plates. The inhomogeneous microstructure, stress corrosion cracking (SCC) resistance and strength of AA7085 thick plate (160 mm) at T/2, T/4, and surface position using mechanical tests, double cantilever beam (DCB) crack extension tests and electron microscopy experiments. The results show that the ultimate tensile strength, yield strength and elongation of the T/2 position are slightly lower than those of the surface position, but the SCC resistance of the T/2 position is significantly higher than that of the surface position. The reason is that larger discontinuously quench-induced grain boundary precipitates (Q-GBPs), and lower Zn and Mg elemental content of GBPs (including Q-GBPs and age-induced GBPs (A-GBPs)) and grain boundaries (GBs). Furthermore, it is newly found that the mechanical effects of larger-sized low aspect ratio unrecrystallized grains contribute significantly to the excellent SCC resistance of the T/2 position. The large size grain structure makes short-range SCC cracks along the large-angle GB more tortuous at T/2, improving the stress intensity required for sustained crack extension. In addition, the high GB triple junction deflection angle resulting from a low aspect ratio grain structure at T/2 improves the average driving force required for crack extension and drive force reduction after localized crack growth.

Microstructure homogeneity and its role in the mechanical properties of the magnetic pulse welded steel/Al tubular joint

The steel and aluminum alloy tubes were successfully joined by magnetic pulse welding (MPW). Part of the joints fractured at the interface, yet part of them fractured at the base metal (BM) of aluminum alloy. The tensile test results revealed a fluctuation of the mechanical properties of the steel/Al MPW joints, demonstrating the microstructure inhomogeneity of the MPW joints. The typical wavy interfacial morphology could be observed at the interface of the MPW joints. The element transition zone composed of elements Fe and Al were detected while no obvious intermetallic compound (IMC) layer could be traced. The good mechanical properties of steel/Al MPW joints could be attributed to the longer effective bonding length and larger element transition area. Besides, the grain refinement was observed at the interface of the MPW joint, which explained its microhardness increase.

Quasi-Isotropy Structure and Characteristics of the Ultrasonic-Assisted WAAM High-Toughness Al Alloy

Wire Arc Additive Manufacturing (WAAM) has emerged as a highly promising method for the production of large-scale metallic structures; nonetheless, the presence of microstructural inhomogeneities, anisotropic properties, and porosity defects within WAAM Al alloys has substantially hindered their broader application. To surmount these obstacles, ultrasonic-assisted WAAM was applied in the fabrication of thin-wall structures utilizing 7075 Al alloy. This study investigates the effects of ultrasonic-assisted Wire Arc Additive Manufacturing (WAAM) on the structural and mechanical properties of 7075 Al alloy specimens. Microstructural analysis showed a significant refinement in grain distribution, with the average grain size notably reduced, enhancing the material’s homogeneity. Porosity across the specimens was quantified, showing a decrease in values from the upper (0.02151) to the middle (0.01347) and lower sections (0.01785), correlating with the rapid cooling effects of WAAM. Mechanical testing revealed that ultrasonic application contributes to a consistent hardness pattern, with measurements averaging 70.71 HV0.1 horizontally and 71.23 HV0.1 vertically, and significantly impacts tensile strength; the horizontally oriented specimen exhibited a tensile strength of 236.03 MPa, a yield strength of 90.29 MPa, and an elongation of 31.10% compared to the vertically oriented specimen which showed reduced mechanical properties due to the presence of defects such as porosity and cracks. The fracture morphology analysis confirmed a predominantly ductile fracture mode, supported by the widespread distribution of dimples on the fracture surface. The integration of ultrasonic vibrations not only refined the grain structure but also modified the secondary phase distribution, enhancing the quasi-isotropic properties of the alloy. These results underline the potential of ultrasonic-assisted WAAM in improving the performance of the 7075 Al alloy for critical applications in the aerospace and automotive industries, suggesting a promising direction for future research and technological advancement in additive manufacturing processes.

Numerical simulation of friction extrusion: process characteristics and material deformation due to friction

This study employs a finite element thermo-mechanical model, using a Lagrangian incremental setting to investigate friction extrusion (FE) under varying process conditions. The incorporation of rotation in FE generates substantial frictional heat, leading to significantly reduced process forces in comparison to conventional extrusion (CE). The model reveals the interplay between temperature, strain, and strain rate across different microstructural zones of the resulting wire. Specifically, the sticking friction condition in FE enhances initial shear deformation, aligning with a homogeneous spatial strain distribution and predicting complete grain refinement in the extruded wire, as per Zener-Hollomon calculations. On the other hand, under the sliding friction condition in FE, the shear deformation is reduced which results in an inhomogeneous microstructure in the extruded wire. The analysis of material flow in the workpiece reveals distinct transitions from the base material to the thermo-mechanically affected zones. The simulated process force, thermal history, and microstructure during sliding friction conditions align well with the findings from performed friction extrusion experiments.

Investigation of microstructural evolution and mechanical properties for in-service nickel-based superalloy

In this study, the microstructural evolutions are systematically investigated in the IN718 alloy that has been in-service for eight years. Correspondingly, the effect of in-service process on mechanical properties are explored in terms of tensile properties, fatigue performance and crack growth behavior. Results show that the grain sizes at different sampling locations vary from 9.8 to 15.5 μm, exhibiting the inhomogeneous microstructures for the in-service IN718 alloy. The volume fraction of δ phase and kernel average misorientation (KAM) at outermost layer are the maximum ones, followed by the middle and innermost layers. In addition, the high magnitude of δ phase is caused by the transformation from strengthening phase γ′′. From the perspective of mechanical properties, the in-service IN718 alloy can maintain excellent yield strength and elongation at the high temperature of 650 °C, while the tensile performance is degenerated at room temperature (RT) compared with those of new IN718 alloy. The fatigue life at 650 °C is similar to that at RT under the stress levels lower than 600 MPa. As the stress level increases to 800 MPa, an obvious decrease in fatigue life at 650 °C compared with that at RT. This special fatigue performance is revealed based on the fractography examinations under different loading conditions. Moreover, the investigation of fatigue crack growth for the in-service IN718 alloy is carried out under different stress ratio and temperatures.

Effect of laser beam wobbling and welding speed in X80 steel wire-fed laser root welds

A wobble laser was combined with a wire feed during laser root welding of X80 pipeline steel. The enlarged laser irradiation area and molten pool resulting from the laser beam wobbling provided a better gap-bridging ability, which is critical during laser welding of thick pipes. Applying laser beam wobbling enabled better control of filler metal dilution, which determined the weld metal microstructure and mechanical properties. In the present work, more bainite along with reduced acicular ferrite was formed in the wobble laser weld, due to the effect of dilution resulting from increased base material melting during wobbling beam, along with an inhomogeneous fusion zone microstructure. The instrumented indentation testing was utilized for the first time to distinguish the local yield strength variation of different regions of the fine weld zones, allowing one to verify if the weld metal strength meet the target value in industrial standards. As the productivity being improved when the welding speed increased from 1.0 to 1.5 m/min, the presence of more low temperature transformation products generated with a faster cooling led to a 26 HV higher hardness and a 70 MPa higher yield strength in the upper region of the fusion zone.

Toward a circular economy: zero-waste manufacturing of carbon fiber-reinforced thermoplastic composites

Fiber-reinforced composites are becoming ubiquitous as a way of lightweighting in the wind, aerospace, and automotive industries, but current recycling technologies fall short of a circular economy. In this work, fiber-reinforced composites made of recycled carbon fiber and polyphenylene sulfide were recycled and remanufactured using common processing technologies such as compression and injection molding. An industrially viable size-exclusive sieving technique was used to retain fiber length and reduce variability in the mechanical properties of the remanufactured composites. Fiber length reduction alone could not explain the strength reductions apparent in the composites, which we propose are due to microstructural inhomogeneity as defined by poor dispersion of the fibers. Future recycling efforts must focus on fiber length retention and good dispersion to make composite remanufacturing a viable path toward a circular economy.