Specific Stiffness Research Articles

Mechanical characteristics of biomimetic twisted honeycomb structures fabricated by powder bed fusion

Honeycomb structures have been widely used in aerospace and automotive applications due to their high efficiency, high strength and high specific stiffness. However, most of the reported publications have focused on the surface shape variations of honeycomb structures, and there is a lack of studies on the variations of honeycomb structures with respect to the internal cell walls (Z-direction). To address these issues, this study proposes to combine the torsional design of honeycomb and Bouligand structures to fabricate twisted honeycomb structures (THS) with cell wall (z-direction) variations using powder bed fusion technology. The THS (30°) exhibits excellent specific energy absorption (SEA) performance, and the SEA of THS (0°), THS (60°), and THS (90°) are reduced by 8.5%, 19.7%, and 37.3%, respectively, compared with that of THS (30°) structure, and the THS (30°) has better repeatability. The effects of structural parameters on the energy absorption performance were analyzed. At THS (30°), changing the number of unit cells, wall length and wall thickness has a large effect on the compression performance. The results show that the specific energy absorption performance of THS reaches a maximum value of 74.6 kJ/kg for the number unit cells n = 3, wall length l = 5 mm and wall thickness t = 1 mm.

Fabrication of lightweight polyethersulfone foams with enhanced surface quality and high specific flexural properties using micro‐opening microcellular injection molding

AbstractPolyethersulfone (PES) is distinguished by its exceptional comprehensive properties, making it a highly valued engineering plastic employed in various cutting‐edge fields. However, the high cost of PES limits its wider application in industrial fields. Considering the cost‐reduction advantages of polymer foaming, PES foams were successfully prepared in this work using microcellular injection molding (MIM) and micro‐opening microcellular injection molding (MOMIM) foaming methods. Compared with the MIM foaming method, the PES foam samples prepared by the MOMIM foaming method have better microcellular structure and surface quality. As the micro‐opening distance increased, the cell density of the PES foam samples showed a gradual rise before plateauing, with the cell size remaining relatively constant. As a result, the density of the PES foam sample dropped to 1.07 g/cm3, which is 80.5% of the solid PES sample. Meanwhile, the mechanical properties of the PES foam samples remained robust, with both the specific flexural modulus and the specific flexural strength showing increases as the micro‐opening distance increased. The knowledge obtained from this study provides a method for preparing high‐performance PES foam materials, which will facilitate the application of PES in more civilian fields.

Pseudo‐ductility behavior of carbon/glass hybrid composites with unidirectionally arrayed chopped strands: Experimental and numerical research

AbstractAlthough lightweight fiber‐reinforced polymer (FRP) composites are widely used in various engineering fields due to their high specific strength and modulus, the mutual exclusion of strength and toughness is one of the bottlenecks in the field of FRP design because of the inherent brittleness of fiber themselves. In this research, discontinuous fiber structures with vertical and bi‐angled slits are introduced into the thin‐ply carbon fiber prepreg. The fracture energy and delamination degree of the center carbon fiber layer could be controlled by adjusting the structural parameters to design the pseudo‐ductility of carbon/glass (C/G) hybrid laminates and obtain the higher pseudo‐yield stress. The hybrid specimens with 20 mm slits exhibit obvious pseudo‐ductility, and the pseudo‐ductility strain increases as the C/G ratio increases, while the plateau stress decreases. The larger slit distance provides sufficient propagation space for the delamination damage, which dissipates tensile energy and results in a smoother plateau area of the stress–strain curve. The stress–strain curve of the specimen with a smaller slit exhibits a noticeable rapid load decrease caused by the transient propagation of delamination damage. The peak stress of hybrid laminate with bi‐angled slits shows the highest pseudo‐yield stress. The present finite element model successfully analyzed the pseudo‐ductile damage propagation of C/G hybrid laminates with vertical slits, and the results are in good agreement with the experiments.Highlights Revealed the pseudo‐ductility behavior of carbon/glass hybrid composites. The pseudo‐ductility of carbon/glass hybrid composites is controllable. The pseudo‐ductility strain increases with the increase of C/G ratio.

Probability Prediction of Curing Process-Induced Deformation for V-Shape Composite Structures Based on FEM Method and Data Mining.

Continuous fiber-reinforced composites are increasingly used in industry for their superior specific modulus and strength. The curing process-induced deformation (PID) has been a critical problem during manufacturing, which always exhibits dispersed values even if the curing process curve and structural parameters remain consistent. This work conducted probability prediction of PID for V-shape composite structures based on the FEM method and data mining. A sequential coupling thermal-chemical-mechanical coupling FE model is established in ABAQUS. The prediction accuracy of the included angle between two sides is verified by the experimental results. Material parameter uncertainties are considered for V-shape structures with different radii and thicknesses. Based on the dataset from the FE model, a decision tree is established and trained to analyze the sensitivity and to predict the probability distribution of PID. The results show that PID increases with the coefficients of thermal expansion in the in-plane perpendicular fiber direction and out-of-plane normal direction. The data-mining method is accurate enough for the PID prediction, and its efficiency provides an additional calculation option in engineering applications.

Effect of Pore Architecture of 3D Printed Open Porosity Cellular Structures on Their Resistance to Mechanical Loading: Part I – Experimental Studies

Abstract The development of additive manufacturing (AM) techniques has sparked interest in porous structures that can be customized in terms of size, shape, and arrangement of pores. Porous lattice structure (LS, called also lattice struct) offer superior specific stiffness and strength, making them ideal components for lightweight products with energy absorption and heat transfer capabilities. They find applications in industries such as aerospace, aeronautics, automotive, and bone ingrowth applications. One of the main advantages of additive manufacturing is the freedom of design, control over geometry and architecture, cost and time savings, waste reduction, and product customization. However, the designation of appropriate struct/pore geometry to achieve the desired properties and structure remains a challenge. In this part of the study, five lattice structs with various pore sizes, with two volume fractions for each, and shapes (ellipsoidal, helical, X-shape, trapezoidal, and triangular) were designed and manufactured using selective laser sintering (SLS) additive manufacturing technology. Mechanical properties were tested through uniaxial compression, and the apparent stress-strain curves were analyzed. The results showed that the compression tests revealed both monotonic and non-monotonic stress-strain curves, indicating different compression behaviors among the structures. The helical structure exhibited the highest resistance to compression, while other structures showed similarities in their mechanical properties. In Part II of this study provides a comprehensive analysis of these findings, emphasizing the potential of purpose-designed porous structures for various engineering applications.

Concurrent Topology Optimization of Curved-Plate Structures with Double-Sided Stiffeners

Due to their high specific stiffness, particularly in bending, along with their strong design capabilities, stiffened plates have become a prevalent structural solution in aerospace and various other fields. In pursuit of optimizing such structures, a topology optimization method named Heaviside-function-based directional growth topology parameterization (H-DGTP) was proposed in our previous work. However, this approach is limited to designing planar, single-sided stiffened structures. Thus, this paper extends the scope of this method to encompass double-sided, curved, stiffened panels, presenting a topology optimization technique tailored for such configurations. Specifically, considering the position, shape of the curved panels, and the arrangement and height of the stiffeners as design variables, while prioritizing structural stiffness as the objective, a topology optimization model for double-sided curved stiffened plate structures is established, and the corresponding sensitivities of the objective with respect to the design variables are analytically derived. Numerical examples illustrate that simultaneously optimizing the position and shape of the plate, as well as the layout and height of the stiffeners on both sides of the curved plate, results in greater stiffness compared to optimizing only part of these variables, validating the necessity and effectiveness of the proposed method.

Identification of interfacial strength between carbon fiber and epoxy matrix in CFRP laminates using pulse laser spallation method

Carbon fiber reinforced plastics (CFRP) have high specific strength and specific stiffness and are used in various fields such as aircraft, space structures, automobiles, and other transportation equipment. Since the internal structure of CFRP is very complex, it is very difficult to define failure criteria when external loads are applied. Various methods have been proposed to evaluate the interfacial shear strength between carbon fiber and resin matrix, such as microbond test, rupture test, and pull-out test, but currently no effective method has been proposed to evaluate the tensile strength of the CF/resin interface. In this study, we applied the pulsed laser spallation method, which has been confirmed to be effective for evaluating the adhesion strength of thin films and coating films on substrates, to the evaluation of CFRP. A finite element method based on the Laplace transform was used for the numerical analysis of the unsteady elastodynamic problem. The macroscopic stresses generated by ultrasonic waves excited by pulsed laser irradiation were calculated by inverse analysis using a transfer function with the displacement history of the back surface of the CFRP specimen as supplementary information. Microscopic stresses at the fiber/resin interface were evaluated by the homogenization method, taking into account the effects of fiber arrangement, distance between fibers, and molding residual stress in unidirectionally reinforced CFRP laminates. As a result, this series of investigations revealed that the vertical interfacial stress is dominant with respect to the strength of the fiber/resin interface with the strength of about 54MPa.

Mechanical and thermal property analysis and optimization design of hybrid lattice structure based on triply periodic minimal surfaces

Hybrid lattice structures have significant potential in engineering applications owing to their outstanding mechanical and thermal properties. In this paper, an innovative design strategy for hybrid lattice structures is proposed involving the integration of primitive surfaces with truss lattice configurations. This approach allows for the full exploitation of the mechanical and thermal properties inherent in each component, leading to the development of new hybrid lattice structures. Firstly, the quasi-static compression and fluid-solid coupling heat conduction analysis of the hybrid lattice structure is carried out by numerical simulation. Then the effects of surface wall thickness, and truss diameter on the mechanical and thermal properties of the lattice structure are discussed. Additionally, the mechanical performance of the array hybrid lattice structure is evaluated through quasi-static compression experiments. These experimental results are compared with those from the numerical simulations, validating the accuracy of the simulation model. Finally, a multi-objective optimization model targeting specific elastic modulus and heat dissipation performance (indicated by Nusselt number) is established, in response to the demand of aviation and aerospace industries for lightweight, load-bearing, and heat-dissipating multi-functional integrated lattice design. The non-dominated sorting genetic algorithm is utilized to solve the optimal model, and the distribution of feasible solutions and Pareto front are obtained. The results show that the interpenetrating hybrid lattice structure has a greater improvement in mechanical and thermal properties than the primitive surfaces. This research holds significant implications for the design of multi-performance hybrid lattice structures.

Nonlinear resonant responses of a novel FGM sandwich cylindrical shell structure for supersonic flight vehicles based on 1:1 internal resonance between conjugate modes

A new design scheme for the functionally graded material (FGM) sandwich cylindrical shell structure made of ceramic-FGM-carbon fiber composites is proposed, which is geared towards supersonic flight vehicles and has high specific stiffness and high-temperature resistance. We focus on analyzing the nonlinear resonant responses of the novel FGM sandwich cylindrical shell subjected to external excitation and aerodynamic force. Firstly, the mechanical properties of the novel FGM sandwich material are calculated, and then the nonlinear dynamic model of the FGM sandwich cylindrical shell is established based on the first order shear deformation theory (FSDT) and Hamilton's principle. Due to the axisymmetric property of the cylindrical shell, a 1:1 internal resonance between the driven and companion modes always exists in the perfect cylindrical shell. Taking this into consideration, the nonlinear resonant response problems of the FGM sandwich cylindrical shell are numerically simulated by combining the Galerkin method and the pseudo-arc length continuation method. Finally, the effects of complex parameters such as external excitation, aerodynamic force, aspect ratio, gradient index, and skin-core-skin ratio on the nonlinear resonant responses of the FGM sandwich cylindrical shell are investigated.

Mechanical properties of Al–Si alloy/Si3N4 interpenetrating phase composite based on a preform fabricated at 1200 °C

Interpenetrating phase composites with three-dimensional co-continuous architecture are promising materials for advanced structural applications due to their excellent combination of properties. In this work, a novel and low-cost Al–Si alloy/Si3N4 IPC was fabricated via squeeze infiltration of Al11Si alloy melt into a porous Si3N4 preform manufactured at a low temperature of 1200 °C using H3PO4 as pore-former and binder. Microstructures of IPC show a good infiltration quality and strong interfacial bonding between metal and ceramic phases without any intermediate reaction products. The fabricated IPC exhibited significantly higher specific hardness and stiffness than the Al11Si alloy. Moreover, an excellent damage tolerance, a substantial increase in compressive strength of 420 %, flexural strength of 168 %, and a significant reduction in wear rate of 95 % in the IPC was achieved with respect to Al11Si. The flexural strength and fracture toughness values of the fabricated IPC compare well to values of Al alloy/Si3N4 IPCs reported in the literature, despite being processed using a porous Si3N4 preform fabricated at a much lower temperature.

Multifunctional design of lattice metamaterial with desired thermal expansion behaviors using topology optimization

Designing metamaterials with unprecedented coefficients of thermal expansion (CTEs) is an urgent demand for the majority engineering structures suffering from ambient temperature variation. Current studies on such artificial materials are mainly focused on achieving CTE tunnability through the purposeful design of material microstructure using an intuition based mechanism. In this study, the mechanical properties including maximum bulk modulus, specific stiffness and high thermal conductivity are combined with desired CTEs for designing multifunctional lattice metamaterials through the application of a non-intuitive topology optimization method. Toward this end, the continuous variable of member cross-sectional area is adopted to optimize lattice topology, section sizes of lattice members and material distributions, simultaneously. To meet the manufacturing requirements, an improved member intersection constraint that can cooperate with the present continuous design variable is introduced. A self-programmed routine that can be coupled with any commercial FEA software is developed to implement the present optimization method for the design of lattice metamaterials. Four typical optimization cases corresponding to different practical engineering issues are completed. Compared with the previously reported representative lattice metamaterials that are devised from the intuition or experience of designers, the optimization results obtained in this work demonstrate an obvious superiority in bulk modulus and specific stiffness. Additionally, a bimetallic specimen, fabricated using mechanical processing technology and composed of the metallic constituents Invar and Aluminum alloy, is presented to demonstrate the manufacturability of the optimized lattice microstructures.

Improvement of apparent IFSS and specific modulus of CNT yarns

Due to the high strength of carbon nanotubes (CNTs) significant effort has been devoted to incorporating them into fibers and composites. To maximize their potential in these areas, there must be strong interactions between the CNT structures and the matrix of the composite. For CNT yarn, progress in this area has been limited. In this work, we present a method for modifying CNT yarn which improves the apparent interfacial shear strength (IFSS) by up to 45 %, as measured by single yarn pullout testing. An ammonium peroxide mixture (APM) treatment method is used to modify the yarn, and this is followed by treatment with commercial sizing agents. A tensioned heat treatment method is also employed to limit the effect of APM treatment on strength and modulus. This method increased the specific modulus of CNT yarns by as much as 16 %. The combined heat and chemical treatments yield increases as high as 43 % in IFSS and 6 % in specific tensile modulus while tempering the decreases in specific tensile strength. The yarn is characterized by SEM, EDS and Raman spectroscopy to show surface carbon being removed from the yarn, seemingly without damaging the CNT structures in the yarn. The main mechanism for IFSS increase appears to be removal of non-graphitic material from the yarn and slight oxidation of the yarn surface. The increase seen in IFSS has the potential to improve the performance of CNT yarn/polymer matrix composites for aerospace applications.

Effects of processing temperature, pressure, and fiber volume fraction on mechanical and morphological behaviors of fully-recyclable uni-directional thermoplastic polymer-fiber-reinforced polymers

This work explores a type of composite called thermoplastic polymer-fiber-reinforced polymers (PFRPs), often referred to as self-reinforced composites (SRCs). A representative PFRP was exemplified using unidirectional (UD) ultra-high-molecular-weight polyethylene (UHMWPE) fibers embedded in a high-density polyethylene (HDPE) matrix. The effects of compression molding temperature and pressure on the mechanical and morphological behaviors of the filament-wound PFRPs with various fiber volume fractions (Vf) were experimentally investigated.The results elucidate the evolution of morphologies and tensile properties of the PFRPs due to thermal melting, fiber misalignment from pressure, and Vf-induced structural variance, which has not been comprehensively reported yet. The highest specific tensile strength and modulus of the PFRP laminae reach 600 MPa/(g/cm3) and 31 GPa/(g/cm3), respectively. These properties are comparable to glass-/aramid-fiber-reinforced polymers (GFRPs, GFRTPs, AFRPs, and AFRTPs), with PFRPs exhibiting better ductility (specific strain at peak load ≈ 4%/(g/cm3)) than other common polymer composites.The motivation for this work was the high recyclability of PFRPs, which can be recycled by melting both the fibers and the matrix, and then reshaped them for re-manufacturing composites to maximize the efficiency in material reuse. This process simplifies the implementation of closed-loop recycling, re-manufacturing, and reuse to support sustainability in composites. This work aims to contribute to advancing thermoplastic PFRPs for their potential applications in various industries.

Fatigue Life Prediction for 2060 Aluminium–Lithium Alloy with Impact Damage

The paper investigates the issue of post-impact fatigue damage of the 2060 aluminium–lithium alloy, a representative material of third-generation aluminium–lithium alloys extensively employed in the fuselage of C919 aircraft due to its notable attributes of high specific stiffness and strength. Initial impact damage is identified utilizing a residual stress–strain field obtained from a quasi-static simulation. Then, the continuum damage mechanics approach is applied to predict the fatigue life of the impacted 2060 aluminium–lithium alloy plates accounting for the combined effects of residual stress, plastic damage, and fatigue loading. A comparative analysis between calculated and experimental results is conducted to validate the efficacy of the proposed methodology.

SPI/SA microgels prepared by phase separation improved the water retention and sensory perception of low-salt pork gels

The SPI/SA microgels was prepared using protein-polysaccharide phase separation technology. The morphology, secondary structure, rheological properties and physical properties of the SPI/SA microgels were characterized and evaluated. SPI/SA microgels were added to low-salt pork gels to evaluate their effect on water retention and mechanical properties. The results indicated that the phase separation of SA and SPI in the mixed solution facilitated the formation of a SPI-rich region, reaching the gelation concentration. Upon heating, the hydrophobic groups in the SPI folded inward, resulting in a decrease in α-helix content and an increase in β-sheet content. This led to the formation of SPI/SA microgels with specific storage modulus and swelling properties. The microgels exhibited a uniform particle size, which could be precisely controlled by adjusting the concentrations of SPI and SA or the heating temperature. The addition of SPI/SA microgels improved sensory evaluation and gel strength, increased water holding capacity, and reduced cooking loss of low-salt pork gels. In addition, the SPI/SA microgels have the ability to convert free water into fixed water that is contained within the structure of the SPI/SA microgels in low-salt pork gel, thereby improving their properties in low-salt pork gels.

Mechanical Performance/Cost Ratio Analysis of Carbon/Glass Interlayer and Intralayer Hybrid Composites

Hybrid composites combining carbon and glass fibers are increasingly studied for their potential to enhance mechanical properties and cost efficiency. Understanding how different hybrid structures influence these properties is critical for optimizing material design and application. In this paper, the mechanical properties of carbon/glass (C/G) interlayer and intralayer hybrid composites, including tensile, compressive, and flexural properties, were tested, and the cost performances of hybrid composites were analyzed to assess the economic feasibility of different stacking configurations. It was revealed that the specific tensile, compressive, and flexural modulus/cost and strength/cost ratios of interlayer and intralayer hybrid composites decreased with increasing carbon fiber content, indicating that adding carbon fiber reduced cost performance. With the combined hybrid ratio and the interlayer structure with glass fiber sandwiching carbon fiber, the tensile and compressive properties were the most cost-effective. When the dispersion degree of the intralayer hybrid structure was 0, the tensile and compressive properties were the most cost-effective. Specifically, for intralayer hybrid composites with a dispersion degree of 0 and C:G = 1:4, the specific tensile strength/cost ratio was 6.7 × 104 N·m/USD, and the specific compressive modulus and strength/cost ratio was 3.8 × 106 N·m/USD and 4.7 × 103 N·m/USD, respectively. However, the flexural performance/cost ratio was found to be opposite to the tensile and compressive results. When carbon fiber was distributed in the bottom layer or used to sandwich the glass fiber, the flexural performance/cost ratio of interlayer hybrid composites was nearly as good as that of glass fiber. Moreover, by considering the working condition of composites, the cost performance of mechanical properties can be optimized and improved through careful design of hybrid ratios and stacking structures.

Topology optimization of finite strain elastoplastic materials using continuous adjoint method: Formulation, implementation, and applications

This study presents a unified formulation of topology optimization for finite strain elastoplastic materials. As the primal problem to describe the elastoplastic behavior, we consider the standard J2-plasticity model incorporated into Neo-Hookean elasticity within the finite strain framework. For the optimization problem, the objective function is set to accommodate both single and multiple objectives, the latter of which is realized by weighting each sub-function. The continuous adjoint method is employed to derive the sensitivity, which is a general form that accepts any kind of discretization method. Then, the governing equations of the adjoint problem are derived as a format that holds at any moment and at any location in the continuum body or on its boundary. Accordingly, the proposed formulation is independent of any requirements in numerical implementation. In addition, the reaction–diffusion equation is used to update the design variable in an optimizing process, for which the continuous distribution of the design variable as well as material properties are maintained. Two specific optimization problems, stiffness maximization and plastic hardening maximization, for two and three-dimensional structures are presented to demonstrate the ability of the proposed formulation.

Experimental Analysis of the Low-Velocity Impact and CAI Properties of 3D Four-Directional Braided Composites after Hygrothermal Aging.

Three-dimensional braided composites (3D-BCs) have better specific strength and stiffness than two-dimensional planar composites (2D-PCs), so they are widely used in modern industrial fields. In this paper, two kinds of 3D four-directional braided composites (3D4d-BCs) with different braided angles (15°, denoted as H15, and 30°, denoted as H30) were subjected to hydrothermal aging treatments, low-velocity impact (LVI) tests, and compression after impact (CAI) tests under different conditions. This study systematically studied the hygroscopic behavior and the effect of hygrothermal aging on the mechanical properties of 3D4d-BC. The results show that higher temperatures and smaller weaving angles can significantly improve the moisture absorption equilibrium content. When the moisture absorption content is balanced, the energy absorption effect of 3D4d-BC is better, but the integrity and residual compression rate will be reduced. Due to the intervention of oxygen molecules, the interface properties between the matrix and the composite material will be reduced, so the compressive strength will be further reduced. In the LVI test, the peak impact load of H15 is low. In CAI tests, the failure of H15 mainly occurs on the side, and the failure form is buckling failure. The main failure direction of H30 is 45° shear failure.

Compound nested lattices with programmable isotropy and elastic stiffness up to the theoretical limit

A novel class of compound structures, which consists of 2 types of unit cell geometries occupying different sites in the lattice (i.e. compound lattice) was investigated. The arrangement and volume ratio of the 2 unit cell geometries were varied, and it was found that the compound lattices can exhibit up to 4 distinct geometries – 2 from the unit cells and 2 supra-structures from the arrangement of each type of unit cell. In stiffness optimization, the material re-organization tends to emphasize the stiffest of the 4 geometries and collapse the hierarchical compound lattice into a single-level structure. In isotropy optimization, unit cells had to be arranged into supra-structures with an anisotropy profile opposite to that of their geometries. These insights led to the introduction of the compound nested lattices, which exhibited higher specific moduli than previous isotropic designs. The compound nested 1pSC:512pFCC lattice, in particular, reached 97.9 % of the Hashin-Shtrikman upper bound at relative density = 0.6, which is the closest approach to the theoretical maximum ever reported.

Mechanical analysis and bionic improvement on buckling of CFRP tubes with high energy absorption capacity

Fiber-reinforced composite tubes have remarkable advantages in energy absorption due to the high specific strength, stiffness, and fracture energy, etc. While, the energy absorption capacity is severely dominated by buckling deformation. To this end, the buckling behaviors and corresponding mechanism of CFRP (carbon fiber reinforced polymer) tubes are systematically investigated in this work. Furthermore, an advanced bionic method referring to bamboo and human bones is adopted to improve the buckling. To effectively analyze the buckling, drop weight impact experiments and corresponding numerical simulations are carried out. The results show that the specific energy absorption (SEA) of CFRP tubes is significantly affected by the diameter-to-height ratio and fiber ply direction, and the influencing mechanism is excessive buckling caused by the geometric characteristics and brittle failure of CFRP. At last, the SEA of CFRP tubes were improved through bio-inspired multi-layered metal/composite hybrid, where the buckling is suppressed reasonably well. The conclusions drawn would be inspiring or guiding the optimal design of high energy-absorbing composite tubes in engineering application.