New toughening concepts for ceramic composites from rigid natural materials

3D-printed bioinspired spicules: Strengthening and toughening via stereolithography

Recently, the replication of biological microstructures has garnered significant attention due to their superior flexural strength and toughness, coupled with lightweight structures. Among the most intriguing biological microstructures renowned for their flexural strength are those found in the Euplectella Aspergillum (EA) marine sponges. The remarkable strength of this sponge is attributed to its complex microstructure, which consists of concentric cylindrical layers known as spicules with organic interlayers. These features effectively impede large crack propagation, imparting extraordinary mechanical properties. However, there have been limited studies aimed at mimicking the spicule microstructure. In this study, structures inspired by spicules were designed and fabricated using the stereolithography (SLA) 3D printing technique. The mechanical properties of concentric cylindrical structures (CCSs) inspired by the spicule microstructure were evaluated, considering factors such as the wall thickness of the cylinders, the number of layers, and core diameter, all of which significantly affect the mechanical response. These results were compared with those obtained from solid rods used as solid samples. The findings indicated that CCSs with five layers or fewer exhibited a flexural strength close to or higher than that of solid rods. Particularly, samples with 4 and 5 cylindrical layers displayed architecture similar to natural spicules. Moreover, in all CCSs, the absorbed energy was at least 3-4 times higher than solid rods. Conversely, CCSs with a cylinder wall thickness of 0.65 mm exhibited a more brittle behavior under the 3-point bending test than those with 0.35 mm and 0.5 mm wall thicknesses. CCSs demonstrated greater resistance to failure, displaying different crack propagation patterns and shear stress distributions under the bending test compared to solid rods. These results underscore that replicating the structure of spicules and producing structures with concentric cylindrical layers can transform a brittle structure into a more flexible one, particularly in load-bearing applications.

Aligning curved stacking bands to simultaneously strengthen and toughen lamellar materials

A layered architecture endows structural materials like nacre and biomimetic ceramics with enhanced mechanical performance because it introduces multiple strengthening and toughening mechanisms. Yet present studies predominantly involve enhancing the alignment in planar lamellar structures, and the effects of the stacking curvature have largely remained unexplored. Here we find that ordered curved stacking bands in lamellar structures act as a new structural mechanism to simultaneously improve strength and toughness. Aligned curved bands increase interlayer frictional resistance to show a strengthening effect and suppress the crack propagation to show an extrinsic toughening effect. In prototypical graphene oxide films, rational regulation of the intervals and orientations of curved bands bring a maximum 162% improvement in strength and 183% improvement in toughness simultaneously. Our results reveal the hidden effects of the stacking curvature on the mechanical behaviors of lamellar materials, opening an extra design dimension to fabricate stronger and tougher structural materials.

Biomimetic bi-material designs for additive manufacturing

Superior material properties have been recently exhibited under the concept of biomimetic designs, where the material architectures are inspired by nature. In this study, a computational framework is developed to present novel architectured bi-material structures with tunable stiffness, strength, and toughness to be used for additive manufacturing (AM). The structure of natural nacre is mimicked to design robust multilayered structures constructed from hexagonal brittle and hard building blocks bonded with soft materials and supports. A set of computational models consisting of fully bonded zones, while allowing for interlayer interactions are created to accurately mimic the interplay between the hard and soft organic phases. As required for such complex designs, the numerical constraints are properly set to run quasi-static non-linear explicit analysis, which allow for a 3× faster analysis with higher efficiency and 2× lower computational cost, when compared to static analysis. The models are used to assess the stiffness, strength and toughness of bi-material beams when subjected to a flexural three-point bending load. The influence of structural features like the soft-to-hard volume ratio (i.e. the distance between each building block, its aspect ratio, and overlap length), material features (e.g. the stiffness ratio of the hard-to-soft phases), the plastic strain failure of soft phase, and AM features (e.g. different types of within-layer/sandwiched supports) are systematically investigated. The results revealed that the toughness of the architectured beams was enhanced by up to 25% when compared to a monolithic structure. This improvement is due to the frictional tile sliding in the brittle phase and the extensive shear plastic deformation of the soft interfaces. This work provides compatible designs to facilitate the AM of nacre-based bi-martial structures with balanced/tailored mechanical performance and to understand the influence of the architectural parameters.

Effects of alternatively used thermal treatments on the mechanical and fracture behavior of dental resin composites with varying filler content

The purpose of this study was two-fold: (i) to investigate whether the thermal treatment of direct dental resin composites (RCs) using microwave or autoclave heating cycles would modify the materials' strength as compared to the protocol without heating (control); and (ii) to compare the mechanical performance of direct and indirect RCs. Three RCs (from 3M ESPE) were tested: one indirect (Sinfony); and two direct materials (microhybrid - Filtek Z250; and nanofilled - Filtek Z350). Specimens from the direct RCs were prepared and randomly allocated into three groups according to the thermal treatment (n = 10): Control - no thermal treatment was performed; Microwave - the wet heating was performed using a microwave oven; and Autoclave - the wet heating was performed in an autoclave oven. The indirect RC was prepared following the instructions of the manufacturer. All materials were tested using flexural strength, elastic modulus, work of fracture (Wf), microhardness, and scanning electron microscopy (SEM) analyses. Data were analyzed with ANOVA and Tukey as well as Weibull analysis (α = 0.05). The thermal treatments tended to produce slight changes in the topography of direct RCs, especially by the autoclave' wet heating. Overall, the physico-mechanical properties changed after thermal treatment, although this effect was dependent on the type of RC and on the heating protocol. Sinfony showed the lowest modulus and hardness of the study, although it was the most compliant system (higher work of fracture). The load-deflection ability was also greater for the indirect RC. Reliability of the tested materials was similar among each other (p > 0.05). In conclusion, the alternative thermal treatments suggested here may significantly influence some aspects of the mechanical behavior of dental resin composites, with negative effects relying on both the chemical composition of the restorative material as well as on the wet heating protocol used. Clinicians should be aware of the possible effects that additional wet heating of direct resin composites using microwave or autoclave thermal protocols as performed here could have on the overall fracture and mechanical responses during loading circumstances.

Lamellar architectures in stiff biomaterials may not always be templates for enhancing toughness in composites

The layered architecture of stiff biological materials often endows them with surprisingly high fracture toughness in spite of their brittle ceramic constituents. Understanding the link between organic-inorganic layered architectures and toughness could help to identify new ways to improve the toughness of biomimetic engineering composites. We study the cylindrically layered architecture found in the spicules of the marine sponge Euplectella aspergillum. We cut micrometer-size notches in the spicules and measure their initiation toughness and average crack growth resistance using flexural tests. We find that while the spicule's architecture provides toughness enhancements, these enhancements are relatively small compared to prototypically tough biological materials, like nacre. We investigate these modest toughness enhancements using computational fracture mechanics simulations.

Mechanical energy dissipation in natural ceramic composites

Ceramics and glasses, in their monolithic forms, typically exhibit low fracture toughness values, but rigid natural marine ceramic and glass composites have shown remarkable resistance to mechanical failure. This has been observed in load-extension behavior by recognizing that the total area under the curve, notably the part beyond the yield point, often conveys substantial capacity to carry mechanical load. The mechanisms underlying the latter observations are proposed as defining factors for toughness that provide resistance to failure, or capability to dissipate energy, rather than fracture toughness. Such behavior is exhibited in the spicules of glass sponges and in mollusk shells. There are a number of similarities in the manner in which energy dissipation takes place in both sponges and mollusks. It was observed that crack diversion, a new form of crack bridging, creation of new surface area, and other important energy-dissipating mechanisms occur and aid in "toughening". Crack tolerance, key to energy dissipation in these natural composite materials, is assisted by promoting energy distribution over large volumes of loaded specimens by minor components of organic constituents that also serve important roles as adhesives. Viscoelastic deformation was a notable characteristic of the organic component. Some of these energy-dissipating modes and characteristics were found to be quite different from the toughening mechanisms that are utilized for more conventional structural composites. Complementary to those mechanisms found in rigid natural ceramic/organic composites, layered architectures and very thin organic layers played major roles in energy dissipation in these structures. It has been demonstrated in rigid natural marine composites that not only architecture, but also the mechanical behavior of the individual constituents, the nature of the interfaces, and interfacial bonding play important roles in energy dissipation. Additionally, the controlling effects of thin organic layers have been observed in other natural ceramic composite structures, such as teeth and bones, indicating that a variety of similar energy dissipating mechanisms in natural ceramic composites may operate as means to resist failure.

A new structure-property connection in the skeletal elements of the marine sponge Tethya aurantia that guards against buckling instability

We identify a new structure-property connection in the skeletal elements of the marine sponge Tethya aurantia. The skeletal elements, known as spicules, are millimeter-long, axisymmetric, silica rods that are tapered along their lengths. Mechanical designs in other structural biomaterials, such as nacre and bone, have been studied primarily for their benefits to toughness properties. The structure-property connection we identify, however, falls in the entirely new category of buckling resistance. We use computational mechanics calculations and information about the spicules' arrangement within the sponge to develop a structural mechanics model for the spicules. We use our structural mechanics model along with measurements of the spicules' shape to estimate the load they can transmit before buckling. Compared to a cylinder with the same length and volume, we predict that the spicules' shape enhances this critical load by up to 30%. We also find that the spicules' shape is close to the shape of the column that is optimized to transmit the largest load before buckling. In man-made structures, many strategies are used to prevent buckling. We find, however, that the spicules use a completely new strategy. We hope our discussion will generate a greater appreciation for nature's ability to produce beneficial designs.

Interphase tuning for stronger and tougher composites

The development of composite materials that are simultaneously strong and tough is one of the most active topics of current material science. Observations of biological structural materials show that adequate introduction of reinforcements and interfaces, or interphases, at different scales usually improves toughness, without reduction in strength. The prospect of interphase properties tuning may lead to further increases in material toughness. Here we use evaporation-driven self-assembly (EDSA) to deposit a thin network of multi-wall carbon nanotubes on ceramic surfaces, thereby generating an interphase reinforcing layer in a multiscale laminated ceramic composite. Both strength and toughness are improved by up to 90%, while keeping the overall volume fraction of nanotubes in a composite below 0.012%, making it a most effective toughening and reinforcement technique.

The role of organic proteins on the crack growth resistance of human enamel

With only 1% protein by weight, tooth enamel is the most highly mineralized tissue in mammals. The focus of this study was to evaluate contributions of the proteins on the fracture resistance of this unique structural material. Sections of enamel were obtained from the cusps of human molars and the crack growth resistance was quantified using a conventional fracture mechanics approach with complementary finite element analysis. In selected specimens the proteins were extracted using a potassium hydroxide treatment. Removal of the proteins resulted in approximately 40% decrease in the fracture toughness with respect to the fully proteinized control. The loss of organic content was most detrimental to the extrinsic toughening mechanisms, causing over 80% reduction in their contribution to the total energy to fracture. This degradation occurred by embrittlement of the unbroken bridging ligaments and consequent reduction in the crack closure stress. Although the organic content of tooth enamel is very small, it is essential to crack growth toughening by facilitating the formation of unbroken ligaments and in fortifying their potency. Replicating functions of the organic content will be critical to the successful development of bio-inspired materials that are designed for fracture resistance.

Morphogenesis and mechanostabilization of complex natural and 3D printed shapes

The natural selection and the evolutionary optimization of complex shapes in nature are closely related to their functions. Mechanostabilization of shape of biological structure via morphogenesis has several beautiful examples. With the help of simple mechanics-based modeling and experiments, we show an important causality between natural shape selection as evolutionary outcome and the mechanostabilization of seashells. The effect of biological growth on the mechanostabilization process is identified with examples of two natural shapes of seashells, one having a diametrically converging localization of stresses and the other having a helicoidally concentric localization of stresses. We demonstrate how the evolved shape enables predictable protection of soft body parts of the species. The effect of bioavailability of natural material is found to be a secondary factor compared to shape selectivity, where material microstructure only acts as a constraint to evolutionary optimization. This is confirmed by comparing the mechanostabilization behavior of three-dimensionally printed synthetic polymer structural shapes with that of natural seashells consisting of ceramic and protein. This study also highlights interesting possibilities in achieving a new design of structures made of ordinary materials which have bio-inspired optimization objectives.

An investigation into mechanical strength of exoskeleton of hydrothermal vent shrimp (Rimicaris exoculata) and shallow water shrimp (Pandalus platyceros) at elevated temperatures

This investigation reports a comparison of the exoskeleton mechanical strength of deep sea shrimp species Rimicaris exoculata and shallow water shrimp species Pandalus platyceros at temperatures ranging from 25°C to 80°C using nanoindentation experiments. Scanning Electron Microscopy (SEM) observations suggest that both shrimp exoskeletons have the Bouligand structure. Differences in the structural arrangement and chemical composition of both shrimps are highlighted by SEM and EDX (Energy Dispersive X-ray) analyses. The variation in the elastic moduli with temperature is found to be correlated with the measured compositional differences. The reduced modulus of R. exoculata is 8.26±0.89GPa at 25°C that reduces to 7.61±0.65GPa at 80°C. The corresponding decrease in the reduced modulus of P. platyceros is from 27.38±2.3GPa at 25°C to 24.58±1.71GPa at 80°C. The decrease in reduced moduli as a function of temperature is found to be dependent on the extent of calcium based minerals in exoskeleton of both types of shrimp exoskeletons.

On flaw tolerance of nacre: a theoretical study

As a natural composite, nacre has an elegant staggered 'brick-and-mortar' microstructure consisting of mineral platelets glued by organic macromolecules, which endows the material with superior mechanical properties to achieve its biological functions. In this paper, a microstructure-based crack-bridging model is employed to investigate how the strength of nacre is affected by pre-existing structural defects. Our analysis demonstrates that owing to its special microstructure and the toughening effect of platelets, nacre has a superior flaw-tolerance feature. The maximal crack size that does not evidently reduce the tensile strength of nacre is up to tens of micrometres, about three orders higher than that of pure aragonite. Through dimensional analysis, a non-dimensional parameter is proposed to quantify the flaw-tolerance ability of nacreous materials in a wide range of structural parameters. This study provides us some inspirations for optimal design of advanced biomimetic composites.

Optimal characteristic nanosizes of mineral bridges in mollusk nacre

The nanosizes of mineral bridges linking neighboring platelets in various types of mollusk nacre dictate the optimal interfacial strength.

A review of experimental techniques to produce a nacre-like structure

The performance of man-made materials can be improved by exploring new structures inspired by the architecture of biological materials. Natural materials, such as nacre (mother-of-pearl), can have outstanding mechanical properties due to their complicated architecture and hierarchical structure at the nano-, micro- and meso-levels which have evolved over millions of years. This review describes the numerous experimental methods explored to date to produce composites with structures and mechanical properties similar to those of natural nacre. The materials produced have sizes ranging from nanometres to centimetres, processing times varying from a few minutes to several months and a different range of mechanical properties that render them suitable for various applications. For the first time, these techniques have been divided into those producing bulk materials, coatings and free-standing films. This is due to the fact that the material's application strongly depends on its dimensions and different results have been reported by applying the same technique to produce materials with different sizes. The limitations and capabilities of these methodologies have been also described.