Ultimate Tensile Research Articles

Advanced 3D Printing of Polyetherketoneketone Hydroxyapatite Composites via Fused Filament Fabrication with Increased Interlayer Connection.

Additively manufactured implants, surgical guides, and medical devices that would have direct contact with the human body require predictable behaviour when stress is applied during their standard operation. Products built with Fused Filament Fabrication (FFF) possess orthotropic characteristics, thus, it is necessary to determine the properties that can be achieved in the XY- and Z-directions of printing. A concentration of 10 wt% of hydroxyapatite (HA) in polyetherketoneketone (PEKK) matrix was selected as the most promising biomaterial supporting cell attachment for medical applications and was characterized with an Ultimate Tensile Strength (UTS) of 78.3 MPa and 43.9 MPa in the XY- and Z-directions of 3D printing, respectively. The effect of the filler on the crystallization kinetics, which is a key parameter for the selection of semicrystalline materials suitable for 3D printing, was explained. This work clearly shows that only in situ crystallization provides the ability to build parts with a more thermodynamically stable primary form of crystallites.

Optimizing high-entropy alloys using deep neural networks

Exceptional mechanical properties of multi-principal element alloys have been typically achieved through manual trial-and-error approaches. The advances in artificial neural networks (ANN) have recently allowed for the development of predictive alloy design ANN models that take into account a large variety of prior experimental findings. However, when mechanical performance is considered, prior processing protocols (e.g. annealing, cold working) are almost impossible to track across different research groups and material classes. In this work, we propose to reverse the use of the yield stress point, setting it as an explicit input (instead of predictive output) parameter that is then used for the quantification of the material state, towards predicting material properties, such as the Ultimate Tensile Strength (UTS). This novel approach specifically addresses the challenge of predicting and improving ductility, a common issue in existing methods focused on yield stress, hardness, and phases. By combining available, validated databases of eleven elements and 734 total materials, we develop an ANN that receives as input the compositions out of 11 possible elements and the "observed" yield stress. Then, we utilize this model to perform predictions for 5-element concentrated alloys with exceptional UTS. We show that this ANN modeling strategy leads to exceptional confidence scores, and then, we use this ANN model for the design of HEAs, which we further discuss.

A Model for the Effect of Microstructure on the Ultimate Tensile Strength of Cast Irons

AbstractThe aim of the present study is to elucidate the influence of individual microstructural parameters, such as pearlite fraction, nodularity, and eutectic cell size, on the tensile strength (UTS) of cast irons. The UTS model was built by integrating the rule of mixtures for each microstructural component, and the UTS was described as a function of the aforementioned factors. The UTS and the required microstructure parameters for the model calculation were obtained experimentally. In the model, two coefficients were introduced to quantify the influence of the eutectic cell size and the interaction terms for the mixed two components. These coefficients were determined through fitting the experimental data, and the model's accuracy was validated using data not included in the fitting process. The results exhibited reasonable agreement, confirming the model's reliability. The model, thus, offers insights into the influence of each microstructural factor on UTS and serves as a guide for designing alloys to achieve the desired UTS through microstructure modifications.

Optimizing friction stir welding of AA7075 and AA8090 aluminum alloys: a desirability-driven investigation into mechanical and microstructural enhancement

This research explores the multifaceted analysis of a friction-welded joint, employing Central Composite Design of Response Surface Methodology. The study integrates microstructural investigations and fracture analyses to explain the effect of process parameters on mechanical properties. The optimum settings for Friction Stir Welding of AA7075 and AA8090 were determined by assessing desirability indices. These settings comprised a tool rotation speed of 1927.7 rpm, a tool travel speed of 35 mm min−1, and a tool tilt angle of 0.9°. This specific combination yielded a noteworthy combined desirability index of 0.79, considering both Ultimate Tensile Strength (UTS) and Tensile Elongation (TE). Microstructural examinations revealed distinct characteristics in the Heat-Affected Zone (HAZ), Thermo-Mechanically Affected Zone (TMAZ), and Nugget Zone (NZ). Notably, fine grain structure in the NZ was attributed to the stirring effect created by the tool pin. Fracture analyses indicated ductile fractures, with dimple size variation correlating to tensile strength. Lower dimple density in low-strength joints suggested insufficient material mixing during welding. The maximum tensile strength sample exhibited a high dimple density. These findings contribute to a comprehensive understanding of the welding process’s influence on microstructure and fracture characteristics, providing valuable insights for optimizing mechanical properties in friction-welded joints.

Response surface methodology and machine learning optimisations comparisons of recycled AA6061-B4C–ZrO2 hybrid metal matrix composites via hot forging forming process

The optimal conditions of applied factors to reuse Aluminium AA6061 scraps are (450, 500, and 550) ⁰C preheating temperature, (1–15) % Boron Carbide (B4C), and Zirconium (ZrO2) hybrid reinforced particles at 120 min forging time via Hot Forging (HF) process. The response surface methodology (RSM) and machine learning (ML) were established for the optimisations and comparisons towards materials strength structure. The Ultimate Tensile Strength (UTS) strength and Microhardness (MH) were significantly increased by increasing the processed temperature and reinforced particles because of the material dispersion strengthening. The high melting point of particles caused impedance movements of aluminium ceramics dislocations which need higher plastic deformation force and hence increased the material's mechanical and physical properties. But, beyond Al/10 % B4C + 10 % ZrO2 the strength and hardness were decreased due to more particle agglomeration distribution. The optimisation tools of both RSM and ML show high agreement between the reported results of applied parameters towards the materials' strength characterisation. The microstructure analysis of Field Emission Scanning Electron Microscopy (FE-SEM) and Atomic Force Microscope (AFM) provides insights mapping behavioural characterisation supports related to strength and hardness properties. The distribution of different volumes of ceramic particle proportion was highlighted. The environmental impacts were also analysed by employing a life cycle assessment (LCA) to identify energy savings because of its fewer processing steps and produce excellent hybrid materials properties.

Microstructure, mechanical, and wear properties evaluation of Al-Cu based composite using RHA as reinforcement

ABSTRACT This study utilised a two-step stir-cast technique to fabricate Aluminium-based composites reinforced with 5% wt Copper (Cu) and varying weight percentages (1–4% wt) of Rice husk ash (RHA). Our work investigated the role of RHA reinforcement on the microstructure, mechanical properties, and wear characteristics of AlCuRHA composite. Characterisation of the composites and fracture surfaces was performed utilising SEM. The hardness and tensile properties were evaluated. Wear was conducted on the composites in dry and wet conditions using H2SO4 as the medium. The microstructure revealed the homogeneous distribution of the RHA within the AlCu matrix. The hardness of reinforced AlCu is enhanced from 54.24 Hv to 122.74 Hv with an increment of RHA reinforcement from 0 to 4%. The Ultimate tensile (UTS) and specific strengths were noted to increase with increased RHA content from 1 to 4% wt. The ductility levels were reduced with the increase in RHA content. The RHA-reinforced AlCu composite exhibits mixed ductile and brittle fracture modes. The composites with RHA exhibited greater wear resistance. Compared to the dry condition, the composites exhibited improved wear resistance in the acidic environment. The composite with 4 wt% RHA exhibited the lowest wear rates regardless of the environment.

Analysis of load carrying performance for glass fiber reinforced thermoplastic composite pipe under different in-service conditions

Fiber reinforced thermoplastic composite pipe (FRTP) has advantages over traditional metallic counterparts for oil and gas transportation. During in-service the pipe is subjected to different mechanical loads including internal pressure, torsion, and bending. In this work, a special type of continuous glass fiber reinforced thermoplastic composite pipe (DN150-6.4 MPa) is analyzed by finite element method (FEM) under various complex service-in conditions. Stress and strain are investigated for different layers of FRTP to determine the extreme load capacity. Experimental analysis is conducted to validate proposed method. Combining the results from FEM and test, it is concluded that the ultimate internal pressure (burst pressure) of FRTP is 61.7 MPa, the ultimate axial tensile displacement is 66.4 mm, the maximum torsion angle is 71.5°, and the minimum bending radius 978.9 mm. Under different working conditions, the mechanical properties of the FRTP are still surplus under the given load. For the good agreement with experimental data, the FEM modeling can be guide for practical application of FRTP.

Sequential hybridisation of wire and powder-based additive manufacturing of Inconel 718: Mechanical and microstructural characterization

The present study combines the Wire-based DED (W-DED) and Powder-based DED (P-DED) to achieve a high deposition rate and higher feature resolution, respectively, within the single component. The research puts forward a novel Wire-Power (WP) Hybrid DED process, which is realized by sequential deposition of feedstock in Wire and then in Powder form. Based on the deposition-extraction combination, three sample configurations, C1 (Y-X), C2 (X-X) and C3 (Y-Z), were fabricated and characterized for the mechanical properties and microstructural aspects. OM images revealed defect-free P-DED and W-DED interface, while the EBSD analysis showed grain size variations owing to differences in the cooling rates. The Ultimate Tensile Strength (UTS) values of C1 and C2 configurations are about 132.2 and 139.7 % higher in comparison to C3. Low cycle fatigue results showed that the C2 sustained a higher number of completely reversed cycles to failure in comparison to the other configurations. The impact energy absorbed by C3 is the highest, affirming the strong W–P interface.

Ultimate Tensile Strengths and Elastic Moduli at 20 K of Additively Manufactured PA840-GSL, A6061-RAM2, and AlSi10Mg

The additive manufacturing (AM) of polymer matrix composites (PMCs) and metal matrix composites (MMC) systems presents novel opportunities for reducing the mass of aerospace vehicles. These solutions also have the potential to reduce the cost of terrestrial applications where cryogenic temperatures are present. To address this need, this paper explores the mechanical characterization of three AM materials at 20 K: a nylon-based PMC PA840-GSL, and two aluminum-based MMCs A6061-RAM2 and AlSi10Mg. A Cryogenic Accelerated Fatigue Tester (CRAFT) used for the mechanical testing is first detailed. Next, ultimate tensile strengths and elastic moduli of the additively manufactured AlSi10Mg alloy and A6061-RAM2 are obtained. Third, the mechanical performance of an additively manufactured PMC liquid hydrogen tank constituent is collected in addition to an analysis on the effect the processing parameters, such as scan spacing, have on the mechanical behavior. A6061-RAM2 exhibited superior mechanical performance and is recommended for structural applications. Variation of PA840-GSL scan spacing resulted in decreased mechanical performance.

Experimental Investigation of Process Parameters on Strength of Welding Joint in GMAW

The strength value most desired in any welding process is an excellent Ultimate Tensile Strength (UTS) of the weld, compared with the parent metal. Process parameters applied during the welding process ought to be subjected to continuous scrutiny and assessment because of the ever increasing demand for structural and industrial materials with weld joints possessing higher strength values. This study is intended to investigate the inadequacies of existing GMAW welding process parameters utilized by the investigated industrial firm in its signature welding protocol, by suggesting alternative, uniquely crafted, and improved process parameters to replace its existing signature welding protocol, thereby improving the weld results by attaining higher UTS. These suggested process parameters were there after subjected to reported literature, following which optimization was achieved by employing the Taguchi Method. Then in future work we will study the strength on universal testing machine and calculating the results

Ultra strong FCC structured Ni8Cr4Co4Fe6W2 high entropy alloys with high strength and ductility by laser powder bed fusion

The high entropy alloys (HEAs) are widely used in high temperature service environment (such as aviation engine blades) with bright application potential in additive manufacturing. Laser powder bed fusion (LPBF) is technology currently offers the best reproducibility and dimensional accuracy for part production. The unique atomic lattice structure of HEA makes its plastic deformation mechanism different from that of traditional dilution alloy, resulting in the strengthening effect of face-centered cubic high-entropy alloy different from that of traditional metal alloy materials. In this paper, Ni8Cr4Co4Fe6W2 was designed by means of composition control. Its spherical powders with uniform composition were successfully prepared by high temperature remelting spheroidization (PHTR) method, compared with gas atomization (GA) method. The strain rate sensitivity m values of GA-Selective Laser Melting and PHTR-Selective Laser Melting samples were 0.030 and 0.027, respectively. The hardness of Ni8Cr4Co4Fe6W2 high-entropy alloy showed a trend of continuous increase with the decrease of grain size, while the elastic modulus didn’t change much (PHTR-SLM is 193 Gpa and GA-SLM is 189 Gpa). The simulated value of the contact stress decreased by 23 % compared with the theoretical value. The contact radius increased with the increase of plastic deformation in addition to the reduction of contact pressure. The printing sample value of the elongation, yield strength (YS) and Ultimate Tensile Strength (UTS) on PHTR-SLM has increased by 39.6 %, 33.7 % and 25.9 %, respectively in additive manufacturing, compared to GA-SLM. The ability to produce refractory HEAs through PHTR method will make it possible to manufacture complex geometry shapes at a reasonable cost.

Investigation of effect of post weld heat treatment on microhardness and microstructure of auto TIG welded stabilized SA213 TP347H weldments

Investigation explores the weldability of Niobium stabilized TP347H austenitic stainless steel tubes through the application of optimized welding parameters using Auto TIG welding. This research investigates the influence of post weld heat treatment conditions on microhardness, microstructures, sensitization due to Cr23C6 precipitation, presence of Niobium carbides and formation of twin boundaries in the weldment. Extended post weld heat treatment duration resulted in notable decline in microhardness from 280 to 180 VHN within initial 5-h of soaking. Nevertheless, further prolongation of soaking time (10–15 h) exhibited subsequent rise in microhardness levels to 200 VHN in base, weld and heat affected zone. Increase in hardness is attributed to the emergence of annealing twins in base metal and the precipitation of Niobium carbides within weld and heat affected zone, confirmed by advanced analytical scanning electron microscope. Energy dispersive spectrum line mapping reveals presence of Cr23C6 precipitation following 1-h soak at 720 °C. Subsequent prolongation of soaking time (5-h) demonstrates desensitization in the base metal. Additionally, cooling rate of 300 °C/hr during post weld heat treatment reduces required time for microstructure homogenization, resulting in increased hardness compared to 100 °C/hr rate in the weldment. However, beyond a 5-h soaking time, the cooling rate has a negligible impact on microhardness. Ultimate Tensile Stress of 674.82 and 665.28 N/mm2 for TP347H was achieved against the minimum requirement of 515 N/mm2 as per American Society of Mechanical Engineers Section IX standard.

Characterization of bacterial cellulose produced by the KomEt strain isolated from a kombucha SCOBY

Bacterial cellulose (BC) is gaining interest, due to its actual and potential applications in the biomedical, cosmetics and textile industries. In this study, mechanical, thermal, and chemical properties of BC produced from a novel strain, isolated from a kombucha symbiotic culture of bacteria and yeast (SCOBY), were evaluated. The highest obtained yields with this strain, after a 10-day fermentation, were 496 ± 14 g/L (native hydrated) and 19 ± 1 g/L (dry). Compression, including relaxation, and traction tests were performed on BC membranes in a hydrated state. The tested material revealed a 3-phase compression behaviour with a compression modulus of 235 ± 50 Pa. In terms of relaxation in water, BC membranes showed plastic deformation past 50 % compression. Regarding BC membrane under traction, analysis showed a 1090 ± 410 kPa Young Modulus, a 50 ± 10 % Elongation at Break and a 270 ± 80 kPa Ultimate Tensile Strength (UTS). Thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) indicated that BC begins its degradation around 290 °C. Fourier-Transform Infrared spectroscopy (FTIR) of freeze-dried BC membranes confirmed the obtained biofilm to be BC. The results of this study provide valuable information on the potential applications of BC membranes in different industries including textile, biomedical and as a low-cost alternative to some synthetic polymers.

Effect of Heat Treatment on Magnetic Properties of EN8D Steel Used in Automotive Applications

The present study focuses on achieving the optimum combination of mechanical and magnetic properties for EN8D steel. SAE 1010 and EN8D steels are the candidate materials to manufacture the fixed nucleus of the disk-type electro-mechanical horn. Both materials have either good magnetic or mechanical properties. The main function of fixed nucleus is to get magnetized and pull the mobile nucleus towards it. However, as magnetization and demagnetization take place in the range of 300-500 Hz, fixed and mobile nucleus continuously strikes each other at high frequency. Due to such high frequency working condition, fixed nucleus is prone to failure under wear and tear or under fatigue. For this kind of application, a combination of magnetic and mechanical properties is required in the material used to manufacture fixed nucleus. Thus, in current paper, the effects of chemical composition, microstructure, hardness, strength and toughness of EN8D steel before and after austenizing and tempering heat treatment are evaluated and compared with as-rolled EN8D and SAE 1010 steels, which are mostly used for manufacturing fixed nucleus. Magnetic permeability was evaluated using JMatPro software and compared. Austenizing treatment is performed at 900 °C for 1 hour, followed by water quenching. Tempering treatment of the same was performed at 550 °C for 2.5 hours. The Ultimate Tensile Strength (UTS) and hardness of EN8D after heat treatment decreased from 917 to 781 MPa and 269 to 233 HV0.1 respectively. Charpy V-Notch (CVN) toughness of EN8D steel after heat treatment increased from 12 to 45 joules. It indicates that the decrease in strength and hardness resulted into increase in toughness. Microstructure changes from ferrite and pearlite to combination of tempered martensite, ferrite and bainite. Magnetic permeability evaluated by JMatPro software shows increment from 450 to 564 Gauss/Oersted in EN8D steel after heat treatment.
 Keywords: Electro-mechanical horn, fixed nucleus, magnetic permeability, JMatPro, SAE1010 steel, EN8D steel

Enhancing Mechanical Properties of Carbon–Silicon Steel through Two‐Stage Quenching and Partitioning with Bainitic Transformation: Ultimate Tensile Strength of 1875 MPa and Total Elongation of 8.03%

To achieve the desired microstructural properties, the ongoing development and innovation in new structural steels require novel thermal processing. This study aims to improve the mechanical properties of a commercial spring carbon–silicon steel by tailoring its microstructure through a process involving quenching and partitioning (Q&P) followed by bainitic transformation. A two‐stage Q&P process is proposed to generate a nanoscale dispersion of stable retained austenite and carbides within the tempered martensite and bainite microstructure. The resulting tensile properties demonstrate a yield strength of 1280 MPa, an ultimate tensile strength of 1875 MPa, and a total elongation of 8.03%. These values surpass those of conventional spring 9254 steel, highlighting the effectiveness of the thermal treatment design. Microstructure analysis reveals the presence of tempered martensite, bainite sheaves, nanoscale carbides, and aggregates of retained austenite. Moreover, the resulting body‐centered cubic matrix exhibits minimal lattice tetragonality of ≈1.0051, coupled with stable retained austenite featuring a carbon concentration of ≈3.42 ± 0.5 wt%, resulting in outstanding strength–ductility properties. These findings indicate that the proposed two‐stage Q&P process, followed by bainitic transformation, significantly enhances the mechanical properties of carbon–silicon steels, making it a promising candidate for high‐performance spring applications.

Enhancing mechanical properties in Mg microtubes using tubular channel angular pressing-extrusion (TCAPE): A promising severe plastic deformation method

In this study, a novel method, Tubular Channel Angular Pressing-Extrusion (TCAPE), is introduced for manufacturing ultrafine microtubes. This method, integrating Tubular Channel Angular Pressing (TCAP) and microtube extrusion (MTE) processes, reduces the number of stages in the fabrication of ultrafine microtubes while achieving favorable mechanical properties. In the TCAPE process, the tube undergoes Severe Plastic Deformation (SPD) in the shaping region and is subsequently shaped into the desired geometric dimensions through the extrusion process at the end. To investigate the effect of the number of SPD passes on the microstructure and mechanical properties of the produced microtubes, one-pass and two-pass SPD were applied. Metallography, XRD testing, tensile testing, and hardness measurement were employed for analysis. For a one-pass SPD, the sample was processed only through the TCAPE process (TCAP + MTE), while for a two-pass SPD, the sample underwent the TCAP process first and then underwent TCAPE for the second processing step (2TCAP + MTE). Tensile test results indicate an increase in Ultimate Tensile Strength (UTS) from the initial value of 73 MPa–103.1 MPa and 148 MPa, and elongation altered from the initial value of 10 to 7.1 and 17.5 after two-pass SPD. Metallography results show a reduction in grain size from the initial value of 160 μm to 15 μm and 3 μm after two-pass SPD. The TCAPE process, due to applying higher strain (1.955) compared to the TCAP process (1.64), exhibits better performance in refining the microstructure and improving mechanical properties. The hardness and ultimate strength of the TCAPE-processed sample are 13.33% and 13.5% higher than those of the TCAP-processed sample, respectively.

Microstructure and properties of in situ Al2O3 particle-reinforced aluminium alloy lattice rods fabricated by wire-arc-directed energy deposition

Lattice structures have great potential for application in the thermal protection systems of high-performance hypersonic vehicles (Mach > 5). They are lightweight, highly load-bearing and provide good heat insulation. Wire-arc directed energy deposition (WA-DED) is an effective method for preparing lattice structures made from metal lattice rods. A method is proposed to improve the ultimate tensile and compressive strengths of aluminium (Al) alloy lattice rods and lattice structures made by WA-DED. The replacement reaction of Al and NiO generates Al2O3, which was used to improve an Al–Cu alloy (2xxx series). An Al–Cu–NiO system cored wire filled with NiO particles was developed as the raw material for studying WA-DED lattice rods. Then the rod was heat treatment. Tests show that the strength of in situ Al2O3-particle-reinforced Al alloy rods was 281 MPa, which is 13.9% higher than that of Al–Cu 2319 Al alloy deposited rods. Reinforcement also increased the elongation (EL) from 11.3% to 13.5%. Strength is increased by Al and NiO reacting in situ to form an Al2O3 phase with refined grains. Most of the generated Ni is dissolved in Al2Cu to form a nano γ-Al7Cu4Ni phase, which plays a second-phase strengthening role. After T6 heat treatment, the strength and EL of 2319-NiO-cored wire deposited rods was 441 MPa and 10.4%. Fine, needle-like θ’-Al2Cu structures and Al2O3 and γ-Al7Cu4Ni nanoparticles pin dislocations, prevent their movement and improve the mechanical properties of the rod. The compressive strength of a planar lattice structure after T6 heat treatment was 105 MPa and its weight was only 15 g, demonstrating high specific strength. Finally, arc additive manufacturing with the developed 2319-NiO-cored wire was used to fabricate a curved-generatrix-shell pyramid lattice structure for use in the thermal protection cone of a hypersonic vehicle. Its thermal insulation coefficient was 82.5%, demonstrating excellent insulation performance. This study provides insights into the manufacturing of thermal protection systems for lightweight, high-strength and high-heat hypersonic vehicles.

Additive manufacturing of WE43 and modified AZ91D magnesium alloys using the laser engineered net shaping process

Magnesium alloys WE43 and AZ91D offer weight savings for structural applications. WE43 contains rare-earth elements such as yttrium and neodymium, whereas AZ91D and the AZ class of alloys are lower-cost containing aluminium and zinc. This work uses a modified version of the latter, identified as AZ91D*, where calcium and yttrium have been added. Laser Engineered Net Shaping (LENS) equipment was used to investigate the 3D printing behaviour of gas-atomized WE43 and AZ91D* material. Process evaluations were first done using single track laser scans across wrought substrates of WE43 and AZ31. Process parameters were then developed that enabled deposition of build coupons with less than 1% porosity. These were used for microstructural and mechanical property assessments. The energy densities used were in the range of 40 – 60 J/mm² for AZ91D*, while for WE43 a value of 50 J/mm² was selected. A focus of the work was managing the tendency of magnesium materials to fume heavily during deposition, while achieving a deposit with close to nominal density, i.e. having a low incidence of voids or other micro- or macro-structural defects. The porosity of AZ91D* builds did not seem to correlate with increasing deposition energy density, however WE43 builds did, up to a practical limit imposed by generation of excessive fume. WE43 generated much less fume than AZ91D*. Analysis of the input powder materials indicate the presence of oxides on the particle surfaces. The WE43 powders had a noticeable shell of yttrium oxide. The microstructures of WE43 builds show the presence of arc-shaped structures that are likely the same yttrium oxides, partially, or fully ‘unfolded’. Tensile testing was conducted on WE43 build coupons to assess the effect of a T6 heat treatment. The effect on the ultimate tensile and yield strengths was negligible, however the % elongation at break almost doubled. Inspection of the fracture surfaces suggests this was due to a change in mechanism from fracture initiation at sites of lack-of-fusion/un-melted particles, to a more ductile micro-void coalescence. Furthermore, a not previously described microstructure anomaly was observed: the presence of pure elemental magnesium crystallites and films on the fracture surface. These are attributed to condensation of magnesium vapour on previously built layers and are a possible reason for the existence of lack-of-fusion defects. The in-depth study of process fundamentals will enable future work on process fume inhibition based on process optimization and alloy composition with the goal of producing parts for biomedical and lightweighting applications.

Process-Structure-Property Relationship Development in Large-Format Additive Manufacturing: Fiber Alignment and Ultimate Tensile Strength.

Parts made through additive manufacturing (AM) often exhibit mechanical anisotropy due to the time-based deposition of material and processing parameters. In polymer material extrusion (MEX), printed parts have weak points at layer interfaces, perpendicular to the direction of deposition. Poly(lactic acid) with chopped carbon fiber was printed on a large-format pellet printer at various extrusion rates with the same tool pathing to measure the fiber alignment with deposition via two methods and relate it to the ultimate tensile strength (UTS). Within a singular printed bead, an X-ray microscopy (XRM) scan was conducted to produce a reconstruction of the internal microstructure and 3D object data on the length and orientation of fibers. From the scan, discrete images were used in an image analysis technique to determine the fiber alignment to deposition without 3D object data on each fiber's size. Both the object method and the discrete image method showed a negative relationship between the extrusion rate and fiber alignment, with -34.64% and -53.43% alignment per extrusion multiplier, respectively, as the slopes of the linear regression. Tensile testing was conducted to determine the correlation between the fiber alignment and UTS. For all extrusion rates tested, as the extrusion multiplier increased, the percent difference in the UTS decreased, to a minimum of 8.12 ± 14.40%. The use of image analysis for the determination of the fiber alignment provides a possible method for relating the microstructure to the meso-property of AM parts, and the relationship between the microstructure and the properties establishes process-structure-property relationships for large-format AM.

Prospective cold metal working and analysis of deformation susceptibility of CuMg alloys with high magnesium content

Metal alloys designated for cold metal working exhibit much higher strength properties than pure materials due to solid-solution hardening. However, with the increase of mechanical properties its plasticity and workability decreases. Constant development and demand in this area has led to research on many copper alloys, such as copper alloys with high content of magnesium which were never tested before. The limitations regarding cold metal working of CuMg alloys is the main objective of this paper. Here we show that the tested materials exhibit much higher mechanical properties than currently used as electric conductors and carrying-conducting equipment materials such as pure copper, aluminum, M63 brass or CuNiSi alloy. The results were obtained using Hollomon relation, Considére criterion, Gubkin method and hardness measurements. It lead to assessing the prospective cold metal working of CuMg alloys with 2 wt% of magnesium up to 4 wt% of magnesium. The test range included upsetting with 10–50% of cold deformation. It provided the results on evolution of mechanical properties and deformability of tested alloys. Additional information was provided based on the alloys subjected to 50% of strain. The results have proven that as the amount of magnesium increased so did the assessed values, however, it was also linked with increasing friction coefficient. Measured hardness was 2 times higher and calculated Ultimate Tensile Strength (UTS) was even 2.5 times higher in reference to pure copper in the as-cast state. However, with magnesium content at 3.6 wt% or higher, the elevated amount of α + β phase causes brittleness making it impossible to subject these materials to cold metal working processes. We anticipate our assay to be a starting point for more sophisticated models and experimental research concerning cold metal working processes of CuMg alloys of high-strength, which may lead to developing novel and promising set of alloys.