The Beneficial Effect of a TPMS-Based Fillet Shape on the Mechanical Strength of Metal Cubic Lattice Structures

The goal of this paper is to improve the mechanical strength-to-weight ratios of metal cubic lattice structures using unit cells with fillet shapes inspired by triply periodic minimal surfaces (TPMS). The lattice structures here presented were fabricated from AA6082 aluminum alloy using lost-PLA processing. Static and dynamic flat and wedge compression tests were conducted on samples with varying fillet shapes and fill factors. Finite element method simulations followed the static tests to compare numerical predictions with experimental outcomes, revealing a good agreement. The TPSM-type fillet shape induces a triaxial stress state that significantly improves the mechanical strength-to-weight ratio compared to fillet radius-free lattices, which was also confirmed by analytical considerations. Dynamic tests exhibited high resistance to flat impacts, while wedge impacts, involving a high concentrated-load, brought out an increased sensitivity to strain rates with a short plastic deformation followed by abrupt fragmentation, indicating a shift towards brittle behavior.

Fabrication of Two-Layer Aluminum Foam Consisting of Dissimilar Aluminum Alloys Using Optical Heating

Aluminum foam is a lightweight material and has excellent shock-absorbing properties. Various properties of aluminum foam can be obtained by changing the base aluminum alloy. Multi-layer aluminum foam can be fabricated by varying the alloy type of the base aluminum alloy, but with different foaming temperatures, within a single aluminum foam to achieve multiple properties. In this study, we attempted to fabricate a two-layer aluminum foam with the upper layer of a commercially pure aluminum A1050 foam and the lower layer of an Al-Si-Cu aluminum alloy ADC12 foam by using an optical heating device that can heat from both the upper and lower sides. Two types of heating methods were investigated. One is to directly stack the A1050 precursor coated with black toner on top of the ADC12 precursor and to foam it from the top and bottom by optical heating. The other is to place a wire mesh between the ADC12 precursor and the A1050 precursor and place the A1050 precursor on the wire mesh, thereby creating a space between the precursors, which is then foamed by optical heating from the top and bottom. It was shown that both precursors can be foamed and joined, and a two-layer A1050/ADC12 foam can be fabricated for both types of heating methods. In the method in which two precursors were stacked and foamed, even if the light intensity of the halogen lamps on the top and bottom were adjusted, heat conduction occurred between the stacked precursors, and the foaming of each precursor could not be controlled, resulting in tilting of the joining interface. In the method of foaming using a wire mesh with a gap between two precursors, it was found that by adjusting the light intensity, the two precursors can be foamed almost simultaneously and achieve similar pore structures. The joining interface can also be maintained horizontally.

Effect of a Multiaxial Load of Reverse Torsion on Open-Cell Aluminum Foams Behavior

As a main goal of this work, a novel generation of cellular materials has been developed and manufactured by the kelvin cell model to be offered for different multifunctional applications. These Open-Cell Aluminum Foams (OCAF) have 85% porosities of spherical-shaped pores with a diameter of 11 mm. Several foamed square-section specimens were used. This work investigated the impact of different new quasi-static biaxial loading complexities on the mechanical behavior of such foams. Thus, new S-profiled rigs were already designed for examining the behavior of tested foams under biaxial loading conditions with different reverse torsional components named ACTP-S. After testing, their high specific strength and high energy absorption abilities have been characterized. Thus, in addition to the reference uniaxial test, all other tests were conducted at a speed of 5 mm/min. Thus, the mechanical responses of this foam are affected by loading complexities which are simple uniaxial, intermediate-biaxial (Bi-45°), and sever-biaxial (Bi-60°). These results were compared to the classical Absorption using Compression-Torsion Plastique (ACTP) responses. It was concluded that the highest dissipated energy increases with the increase in loading path complexity. Note that the energy absorption of the foam is essentially governed by its collapse mode.

Machine Learning Estimation of Plateau Stress of Aluminum Foam Using X-ray Computed Tomography Images

Owing to its lightweight and excellent shock-absorbing properties, aluminum foam is used in automotive parts and construction materials. If a nondestructive quality assurance method can be established, the application of aluminum foam will be further expanded. In this study, we attempted to estimate the plateau stress of aluminum foam via machine learning (deep learning) using X-ray computed tomography (CT) images of aluminum foam. The plateau stresses estimated by machine learning and those actually obtained using the compression test were almost identical. Consequently, it was shown that plateau stress can be estimated by training using the two-dimensional cross-sectional images obtained nondestructively via X-ray CT imaging.

Preparation and Performance of Water-Active Polyurethane Grouting Material in Engineering: A Review

Polyurethane foam materials have broad application prospects in practical engineering as flame retardants, waterproof coatings, and grout repair materials due to advantages such as light weight, quick forming, and good durability. Due to water's low cost and convenience, water-reactive Polyurethane foam materials are widely used in engineering. The content of the water has a significant effect on the performance of polyurethane foams after molding. Polyurethane foams with anti-seepage and reinforcement effects are used in complex water environments for long durations. This study analyzed the effects of water content on properties and the diffusion mechanism of polyurethane foam materials in water. Additionally, the effect of the water environment on the polyurethane grouting material's properties was summarized. Finally, this study discussed the future research directions of polyurethane foam materials in a water environment.

Analysis of the topological motifs of the cellular structure of the tri-spine horseshoe crab (Tachypleus tridentatus) and its associated mechanical properties

Topological motifs in pore architecture can profoundly influence the structural properties of that architecture, such as its mass, porosity, modulus, strength, and surface permeability. Taking the irregular cellular structure of the tri-spine horseshoe crab as a research model, we present a new approach to the quantitative description and analysis of structure-property-function relationships. We employ a robust skeletonization method to construct a curve-skeleton that relies on high-resolution 3D tomographic data. The topological motifs and mechanical properties of the long-range cellular structure were investigated using the Grasshopper plugin and uniaxial compression test to identify the variation gradient. Finite element analysis was conducted for the sub-volumes to obtain the variation in effective modulus along the three principal directions. The results show that the branch length and node distribution density varied from the tip to the base of the sharp corner. These node types formed a low-connectivity network, in which the node types 3-N and 4-N tended to follow the motifs of ideal planar triangle and tetrahedral configurations, respectively, with the highest proportion of inter-branch angles in the angle ranges of 115-120° and 105-110°. In addition, mapping the mechanical gradients to topological properties indicated that narrower profiles with a given branch length gradient, preferred branch orientation, and network connectedness degree are the main factors that affect the mechanical properties. These factors suggest significant potential for designing a controllable, irregularly cellular structure in terms of both morphology and function.

Numerical Investigation of Impact Behavior of Strut-Based Cellular Structures Designed by Spatial Voronoi Tessellation

Porous materials have significant advantages, such as their light weight and good specific energy absorption. This paper presents the designs of two ordered Voronoi structures, a truncated octahedron (Octa) and a rhombic dodecahedron (Dodeca), based on spatial Voronoi tessellation. Through a numerical analysis, the dynamic behavior, deformation and energy absorption of the two porous structures under different impact energies were explored. According to the energy-absorption index, the effects of porosity, rotating unit cell and unit-cell shape on the energy absorption of the porous structures were quantitatively evaluated. The study shows that, for Dodeca and Octa structures subjected to various impact energies, the force-displacement curves exhibit three modes. The porosity, rotational unit cell and unit-cell shape play a crucial role in affecting the impact resistance of porous structures. The work in this paper proposes an effective way to improve the energy-absorption capacity of porous structures under different impact energies. At the same time, a new understanding of the deformation mechanism of Octa and Dodeca was obtained, which is significant for the impact-resistance design and energy-absorption evaluation of porous structures.

New Insights into Fabrication of Al-Based Foam with Homogeneous Small Pore-Structure Using MgCO3/Zn Composite Powder as a Foaming Agent

Due to its excellent mechanical properties and ultra-lightweight, Al-based foam with homogeneous small pore-structures has wide applicational prospects in many industrial fields. However, during the foaming process of molten Al, it is difficult to manipulate the pore structures of the Al-based foam by means of the ALPORAS© production route due to the violent gas-releasing performance of TiH2 as a traditional foaming agent. Herein, we developed the melt-foaming route, that is, using MgCO3/Zn composite powder as a foaming agent instead of TiH2, the Al-based foam with homogeneous small pore-structures (average diameter was about 1 mm) was prepared successfully. Meanwhile, the decomposition model of the MgCO3/Zn composite powder was proposed and further verified experimentally. The decomposition kinetics of the MgCO3/Zn composite powder was also analyzed. Our findings not only shed light on the practical manufacturing of Al-based foam with homogeneous small pore-structures, but provide an insightful improvement for melt-foaming approaches.

Compressive Mechanics and Hyperelasticity of Ni-Ti Lattice Structures Fabricated by Selective Laser Melting

Additively manufactured Ni-Ti lattice structures have controllable bio/mechanical properties, as well as excellent large deformation and damping properties similar to those of natural bone. They have broad application prospects in the field of bone implantation. Triply Periodic Minimal Surface (TPMS) structures are believed to be the most potential and ideal bionic bone structures. In this work, Ni-Ti Gyroid-type TPMS lattice structures were fabricated by selective laser melting (SLM) and their manufacturing fidelity and compression properties were evaluated. By changing the maximum strain value, the hyperelastic recovery performance under cyclic stress was investigated. The results showed that the Ni-Ti Gyroid lattice structures fabricated by SLM had excellent manufacturability (relative density can reach 98.93%) and mechanical properties (elastic modulus is about 130.8 MPa, ultimate strength is about 2.7 MPa). The hyperelastic cycle testing showed that the elastic modulus, yield strength and ultimate strength of the lattice structures tended to stablilize gradually with increasing numbers of cycles. The residual strain increased with the number of cycles, and as the maximum strain increased from 4% to 8%, the residual strain also increased from 1% to 4%.

A method for the optimal design of low-density polymer foam core sandwiches using FEA and multiobjective optimization of design variables

In this study, a generative method was introduced to determine the optimal design of low-density polymer foam core sandwiches using finite element analysis (FEA) and multi-objective optimization of design variables without needing experiments. The method was also assessed. The sandwich structures were designed based on woven plain carbon fiber fabrics, PVC foam core, and polymer epoxy matrix. The design variables are the core density (40, 48, 60 kg/m3) and the core thickness (16, 20, 25 mm). The sandwich configurations were subjected to FEA under the three-point bending (TPB) loads. The force-reaction curves obtained from FEA were compared to experimental data available in the literature. Excellent agreement was achieved between the experimental and FEA simulated results at the linear elastic region of the curves. Thus, it allowed predicting the bending stiffness of the sandwiches via TPB analysis. Besides, a two-way analysis of variance (ANOVA) was conducted to determine the effects of parameters on sandwich mass and bending load capacity. Multi-objective optimization of design variables was also carried out according to the constructed mathematical models. The method provided in this study eases both designer’s and researcher’s work to obtain the optimal design variables without making costly experiments.

Double-Level Energy Absorption of 3D Printed TPMS Cellular Structures via Wall Thickness Gradient Design

This paper investigates the deformation mechanism and energy absorption behaviour of 316 L triply periodic minimal surface (TPMS) structures with uniform and graded wall thicknesses fabricated by the selective laser melting technique. The uniform P-surface TPMS structure presents a single-level stress plateau for energy absorption and a localized diagonal shear cell failure. A graded strategy was employed to break such localized geometrical deformation to improve the overall energy absorption and to provide a double-level function. Two segments with different wall thicknesses separated by a barrier layer were designed along the compression direction while keeping the same relative density as the uniform structure. The results show that the crushing of the cells of the graded P-surface TPMS structure occurs first within the thin segment and then propagates to the thick segment. The stress–strain response shows apparent double stress plateaus. The stress level and length of each plateau can be adjusted by changing the wall thickness and position of the barrier layer between the two segments. The total energy absorption of the gradient TPMS structure was also found slightly higher than that of the uniform TPMS counterparts. The gradient design of TPMS structures may find applications where the energy absorption requires a double-level feature or a warning function.

Design procedure for triply periodic minimal surface based biomimetic scaffolds

Cellular additively manufactured metallic structures for load-bearing scaffolds in the context of bone tissue engineering (BTE) have emerged as promising candidates. Due to many advantages in terms of morphology, stiffness, strength and permeability compared to conventional truss structures, lattices based on triply periodic minimal surfaces (TPMS) have recently attracted increasing interest for this purpose. In addition, the finite element method (FEM) has been proven to be suitable for accurately predicting the deformation behavior as well as the mechanical properties of geometric structures after appropriate parameter validation based on experimental data. Numerous publications have examined many individual aspects, but conceptual design procedures that consider at least the essential requirements for cortical and trabecular bone simultaneously are still rare. Therefore, this paper presents a numerical approach to first determine the actual admissible design spaces for a choice of TPMS based lattices with respect to key parameters and then weight them with respect to further benefit parameters. The admissible design spaces are limited by pore size, strut size and volume fraction, and the subsequent weighting is based on Young's modulus, cell size and surface area. Additively manufactured beta-Ti-42Nb with a strain stiffness of 60.5GPa is assumed as material. In total, the procedure considers twelve lattice types, consisting of six different TPMS, each as network solid and as sheet solid. The method is used for concrete prediction of suitable TPMS based lattices for cortical bone and trabecular bone. For cortical bone a lattice based on the Schwarz Primitive sheet solid with 67.572μm pore size, 0.5445 volume fraction and 18.758GPa Young's modulus shows to be the best choice. For trabecular bone a lattice based on the Schoen Gyroid network solid with 401.39μm pore size, 0.3 volume fraction and 4.6835GPa Young's modulus is the identified lattice. Finally, a model for a long bone scaffold is generated from these two lattices using functional grading methods in terms of volume fraction, cell size and TPMS type. In particular, the presented procedure allows an efficient estimation for a likely suitable biometric TPMS-based scaffolds. In addition to medical applications, however, the method can also be transferred to numerous other applications in mechanical, civil and electrical engineering.

Transition from Homogeneous to Localized Deformation in Nanoporous Gold

We report a transition from homogeneous deformation to localized densification for nanoporous gold (NPG) under compression, with its solid fraction (φ) increasing to above ∼1/3. Results obtained herein suggest that this transition is inverted compared to that of conventional porous materials. Consequently, under compression, the low-density NPGs with φ<1/3 showed evident strain hardening, whereas a stress plateau was observed for high-density NPGs with φ>1/3, which is contrary to the established notions for conventional porous materials. The ligament pinch-offs and bending-dominated structures are responsible for the homogeneous deformation of low-density NPGs. For high-density NPGs, the compression- or tension-dominated structure enables the collective strain bursts in nanoligaments, resulting in localized densification and stress plateau in their compression curves. In addition to the nanosize effect, the surface-diffusion-mediated topology evolution and the large-scale crystal-lattice coherency arising from the large grain size are also decisive to the mechanical response of dealloyed NPGs, which might be universal for self-organized nanonetwork materials.

Compressive Properties and Failure Mechanisms of Gradient Aluminum Foams Prepared by a Powder Metallurgy Method

A layered gradient aluminum foam was prepared by powder sintering with sodium thiosulfate (Na2S2O3) particles as the cell-forming agent. By cutting, polishing and observing under a microscope, it was found that the aluminum powder particles were not completely melted after sintering but were only combined by surface melting. Based on the quasi-static compression test and the macroscopic diagram of the sample during deformation, the mechanical properties of gradient aluminum foam were studied, and their deformation characteristics and mechanism were analyzed and discussed.

Novel Methodology for Experimental Characterization of Micro-Sandwich Materials

Lightweight components are in demand from the automotive industry, due to legislation regulating greenhouse gas emissions, e.g., CO₂. Traditionally, lightweighting has been done by replacing mild steels with ultra-high strength steel. The development of micro-sandwich materials has received increasing attention due to their formability and potential for replacing steel sheets in automotive bodies. A fundamental requirement for micro-sandwich materials to gain significant market share within the automotive industry is the possibility to simulate manufacturing of components, e.g., cold forming. Thus, reliable methods for characterizing the mechanical properties of the micro-sandwich materials, and in particular their cores, are necessary. In the present work, a novel method for obtaining the out-of-plane properties of micro-sandwich cores is presented. In particular, the out-of-plane properties, i.e., transverse tension/compression and out-of-plane shear are characterized. Test tools are designed and developed for subjecting micro-sandwich specimens to the desired loading conditions and digital image correlation is used to qualitatively analyze displacement fields and fracture of the core. A variation of the response from the material tests is observed, analyzed using statistical methods, i.e., the Weibull distribution. It is found that the suggested method produces reliable and repeatable results, providing a better understanding of micro-sandwich materials. The results produced in the present work may be used as input data for constitutive models, but also for validation of numerical models.

Yttrium Oxide Freeze-Casts: Target Materials for Radioactive Ion Beams

Highly porous yttrium oxide is fabricated as ion beam target material in order to produce radioactive ion beams via the Isotope Separation On Line (ISOL) method. Freeze casting allows the formation of an aligned pore structure in these target materials to improve the isotope release. Aqueous suspensions containing a solid loading of 10, 15, and 20 vol% were solidified with a unidirectional freeze-casting setup. The pore size and pore structure of the yttrium oxide freeze-casts are highly affected by the amount of solid loading. The porosity ranges from 72 to 84% and the crosslinking between the aligned channels increases with increasing solid loading. Thermal aging of the final target materials shows that an operation temperature of 1400 °C for 96 h has no significant effect on the microstructure. Thermo-mechanical calculation results, based on a FLUKA simulation, are compared to measured compressive strength and forecast the mechanical integrity of the target materials during operation. Even though they were developed for the particular purpose of the production of short-lived radioactive isotopes, the yttria freeze-cast scaffolds can serve multiple other purposes, such as catalyst support frameworks or high-temperature fume filters.

Post-corrosion mechanical properties of absorbable open cell iron foams with hollow struts

In-depth analyses of post-corrosion mechanical properties and architecture of open cell iron foams with hollow struts as absorbable bone scaffolds were carried out. Variations in the architectural features of the foams after 14 days of immersion in a Hanks' solution were investigated using micro-computed tomography and scanning electron microscope images. Finite element Kelvin foam model was developed, and the numerical modeling and experimental results were compared against each other. It was observed that the iron foam samples were mostly corroded in the periphery regions. Except for quasi-elastic gradient, other mechanical properties (i.e. compressive strength, yield strength and energy absorbability) decreased monotonically with immersion time. Presence of adherent corrosion products enhanced the load-bearing capacity of the open cell iron foams at small strains. The finite element prediction for the quasi-elastic response of the 14-day corroded foam was in an agreement with the experimental results. This study highlights the importance of considering corrosion mechanism when designing absorbable scaffolds; this is indispensable to offer desirable mechanical properties in porous materials during degradation in a biological environment.

Multi-phase-field simulation of microstructure evolution in metallic foams

This paper represents a model for microstructure formation in metallic foams based on the multi-phase-field approach. The model allows to naturally account for the effect of additives which prevent two gas bubbles from coalescence. By applying a non-merging criterion to the phase fields and at the same time raising the free energy penalty associated with additives, it is possible to completely prevent coalescence of bubbles in the time window of interest and thus focus on the formation of a closed porous microstructure. On the other hand, using a modification of this criterion along with lower free energy barriers we investigate with this model initiation of coalescence and the evolution of open structures. The method is validated and used to simulate foam structure formation both in two and three dimensions.

Numerical evaluation of lightweight ultra high strength steel sandwich for energy absorption

Legislation regarding greenhouse gas emissions forces automotive manufacturers to bring forth new and innovative materials and structures for weight reduction of the body-in-white. The present work evaluates a lightweight ultra high strength steel sandwich concept, with perforated cores, for energy absorption applications. Hat-profile geometries, subjected to crushing, are studied numerically to evaluate specific energy absorption for the sandwich concept and solid hat-profiles of equivalent weight. Precise discretization of the perforated core requires large computational power. In the present work, this is addressed by homogenization, replacing the perforated core with a homogeneous material with equivalent mechanical properties. Input data for the equivalent material is obtained by analyzing a representative volume element, subjected to in-plane loading and out-of-plane bending/twisting using periodic boundary conditions. The homogenized sandwich reduces the number of finite elements and thereby computational time with approximately 95%, while maintaining accuracy with respect to force–displacement response and energy absorption. It is found that specific energy absorption is increased with 8–17%, when comparing solid and sandwich hat profiles of equivalent weight, and that a weight saving of at least 6% is possible for equivalent performance.

Microstructure, mechanical properties, degradation behavior, and biocompatibility of porous Fe-Mn alloys fabricated by sponge impregnation and sintering techniques

In this study, porous iron (Fe)-manganese (Mn) alloys with high porosity were successfully prepared by sponge impregnation and sintering (SIS). The compositions of the porous Fe-Mn alloys were strongly dependent on the sintering temperature, and the Mn content was ~44, 30, and 12 wt.% for alloys sintered at 1100, 1150, and 1200 °C, respectively. The porous Fe-Mn alloys exhibited a well-interconnected porous structure with ~85% porosity and average pore size ranging from 375 to 500 um. The porous Fe-44Mn and Fe-30Mn alloys were mainly composed of a γ-austenite phase, while the porous Fe-12Mn was composed of an α-ferrite phase. The yield strength and elastic modulus of the porous Fe-Mn alloys ranged from 6 to 10 MPa and from 0.12 to 0.37 GPa, respectively, similar to those of cancellous bone. The degradation rate of the porous Fe-Mn alloys decreased over time during immersion in simulated body fluid (SBF), and was 1.0 mm/year for Fe-44Mn, 0.81 mm/year for Fe-30Mn, 0.41 mm/year for Fe-12Mn, and 0.33 mm/year for pure Fe after 14 d SBF immersion. Moreover, the porous Fe-Mn alloys exhibited good biocompatibility with clearly enhanced cell proliferation after direct culturing of osteoblastic MC3T3-E1 cells for 7 d. Thus, these porous Fe-Mn alloys can be anticipated to be promising biodegradable implant materials. STATEMENT OF SIGNIFICANCE: This work reports on porous Fe-Mn alloys with high porosity, suitable mechanical properties and degradation rate, and good biocompatibility. The porous alloys prepared by sponge impregnation and sintering exhibited a well-interconnected porous structure with ~85% porosity and average pore size ranging from 375 to 500 um. The yield strength and elastic modulus of the porous alloys ranged from 6 to 10 MPa and from 0.12 to 0.37 GPa, respectively, similar to those of cancellous bone. The degradation rates in simulated body fluid (SBF) were ~1.0 mm/year for Fe-44Mn, 0.81 mm/year for Fe-30Mn, and 0.41 mm/year for Fe-12Mn, respectively. Moreover, the porous Fe-Mn alloys exhibited good biocompatibility with enhanced cell proliferation after direct culturing of osteoblastic MC3T3-E1 cells.

Effect of Heat Treatment on Gradient Microstructure of AlSi10Mg Lattice Structure Manufactured by Laser Powder Bed Fusion

The present study addressed the effect of heat treatment process on microstructure of an AlSi10Mg lattice structure with a body-centered cubic unit cell manufactured via laser powder bed fusion (LPBF). The as-manufactured lattice specimen exhibited a unique cellular structure composing of primary α-Al phases bounded by α-Al/Si eutectic microstructure. A gradient microstructure (continuous microstructural changes) was found in the node and strut portions composed of the lattice specimen. The microstructure appears more equiaxed and coarser with approaching the bottom surface of both portions. The continuous microstructural changes contributed to a variation in hardness measured at different locations in the as-manufactured lattice specimen. Si particles finely precipitate in the primary α-Al phases, and eutectic Si particle coarsening occurs at an elevated temperature of 300 °C. The microstructural coarsening is more pronounced at a higher temperature. A number of significantly coarsened Si particles and a stable Fe-containing intermetallic phase (β-AlFeSi) were observed at all locations in 530 °C solution-treated specimen. The homogenous microstructure results in a constant hardness value independent of the location in the lattice specimen. These results provide new insights to control the compressive properties of the AlSi10Mg lattice structure manufactured via LPBF by subsequent heat treatment processes.

Electromechanical Vibration Characteristics of Porous Bimorph and Unimorph Doubly Curved Panels

The aim of this study is developing an analytical solution for the free vibration of piezoelectric bimorph and unimorph doubly curved panels with a porous substrate. The panel is assumed to be relatively thick, and the effects of its shear deformation are taken into account. Nonlinear models are considered to describe the variation of mechanical properties and of the electric potential within porous host and piezoelectric layers, respectively. Furthermore, short and open circuit electrical conditions are studied to predict the frequency response for sensing and actuation applications. Employing the first-order shear deformation theory (FSDT), in conjunction with the Hamilton’s variational principle and Maxwell’s equation allows deriving six highly coupled partial differential equations to describe the system dynamics under electromechanical coupling. After analytically solving those equations for simply supported panels, the system frequency response is investigated, for various values of design parameters such as porosity, electrical boundary conditions, and geometry. Moreover, some types of smart panels, including bimorphs and unimorphs layouts, are analyzed. The analysis confirms that the above-mentioned parameters play major roles in the natural frequency response of this system and must be carefully considered in the mechatronic design of this smart structure, although they allow to tailor the system behaviour to the selected application.

Degradation behavior, cytotoxicity, hemolysis, and antibacterial properties of electro-deposited Zn-Cu metal foams as potential biodegradable bone implants

Zinc (Zn) alloys have attracted much attention for biomedical applications due to their biodegradability, biocompatibility, and biological functionalities. Zn alloy foams have high potential to be used as regenerative medical implants by virtue of their porous structure, which allows new bone tissue ingrowth, their low elastic modulus approximating that of natural bone, and their biodegradation, which eliminates the need for follow-up surgery to remove the implants after bone tissue healing. In this context, a biodegradable Zn-Cu foam was fabricated by electrochemical deposition on a foamed Cu template and given a subsequent diffusion heat treatment. The microstructure, mechanical properties, degradation behavior, toxicity, hemolysis percentages, and antibacterial effects of the Zn-Cu foams were assessed for biomedical applications. The Zn-Cu foams exhibited a yield strength of ~12.1 MPa, a plateau strength of 16.8 MPa, and a strain over 50% under compression tests. The corrosion rate of the Zn-Cu foams measured by electrochemical polarization testing was 0.18 mm/y. The Zn-Cu foams showed good blood compatibility with a hemolysis percentage of less than 5%. Cytotoxicity assessment indicated that a 100% concentration of the Zn-Cu foam extract showed clear cytotoxicity against MC3T3-E1 osteoblast cells, but a 12.5% concentration of the extract showed > 90% cell viability. Moreover, the Zn-Cu foams showed good antibacterial effects. STATEMENT OF SIGNIFICANCE: This work reportsa biodegradable Zn-Cu foam with high mechanical strength and ductility, suitable degradation rate, good antibacterial capacity, and good hemolysis property and biocompatibility. The Zn-Cu foam exhibited a yield strength of ~12.1 MPa, a plateau strength of 16.8 MPa, and a strain over 50% under compression tests. The corrosion rate of the Zn-Cu foam measured by electrochemical polarization testing was 0.18 mm/y in Hanks' Solutions. The Zn-Cu foam showed good blood compatibility with a hemolysis percentage of less than 5%. Cytotoxicity assessment indicated that a 12.5% concentration of the foam extract showed > 90% cell viability. Moreover, the Zn-Cu foam showed good antibacterial effects against S. aureus.

Gold Aerogel Monoliths with Tunable Ultralow Densities

Herein we report the fabrication of ultralight gold aerogel monoliths with tunable densities and pore structures. Gold nanowires are prepared at the gram scale by substrate-assisted growth with uniform size, ultrathin diameters, high purity, and a high aspect ratio. Freeze-casting of suspensions of these nanowires produces free-standing, monolithic aerogels with tunable densities from 6 to 23 mg/cm³, which to the best of our knowledge represents the lowest density monolithic gold material. We also demonstrate that the pore geometries created during freeze-casting can be systematically tuned across multiple length scales by the selection of different solvents and excipients in the feedstock suspension. The mechanical behavior of porous materials depends on relative density and pore architectures.

Phoamtonic designs yield sizeable 3D photonic band gaps

We show that it is possible to construct foam-based heterostructures with complete photonic band gaps. Three-dimensional foams are promising candidates for the self-organization of large photonic networks with combinations of physical characteristics that may be useful for applications. The largest band gap found is based on 3D Weaire-Phelan foam, a structure that was originally introduced as a solution to the Kelvin problem of finding the 3D tessellation composed of equal-volume cells that has the least surface area. The photonic band gap has a maximal size of 16.9% (at a volume fraction of 21.6% for a dielectric contrast [Formula: see text]) and a high degree of isotropy, properties that are advantageous in designing photonic waveguides and circuits. We also present results for 2 other foam-based heterostructures based on Kelvin and C15 foams that have somewhat smaller but still significant band gaps.

Mechanical and Corrosion Resistance Enhancement of Closed-Cell Aluminum Foams through Nano-Electrodeposited Composite Coatings

This work aims to improve the properties of aluminum foams including the mechanical properties and corrosion resistance by electrodepositing a SiC/TiN nanoparticles reinforced Ni-Mo coating on the substrate. The coatings were electrodeposited at different voltages, and the morphologies of the coating were detected by SEM (scanning electron microscope) to determine the most suitable voltage. We used XRD (x-ray diffraction) and TEM (transmission electron microscope) to analyze the structure of the coatings. The aluminum foams and the substrates on which the coatings were electrodeposited at a voltage of 6.0 V for different electrodeposition times were compressed on an MTS (an Electro-mechanical Universal Testing Machine) to detect the mechanical properties. The corrosion resistance before and after the electrodeposition experiment was also examined. The results showed that the coating effectively improved the mechanical properties. When the electrodeposition time was changed from 10 min to 40 min, the W_v of the aluminum foams increased from 0.852 J to 2.520 J and the σ_s increased from 1.06 MPa to 2.99 MPa. The corrosion resistance of the aluminum foams was significantly improved after being coated with the Ni-Mo-SiC-TiN nanocomposite coating. The self-corrosion potential, pitting potential, and potential for primary passivation were positively shifted by 294 mV, 99 mV, and 301 mV, respectively. The effect of nanoparticles on the corrosion resistance of the coatings is significant.

Early Compressive Deformation of Closed-Cell Aluminum Foam Based on a Three-Dimensional Realistic Structure

It is well-known that cell morphology plays a vital role in the mechanical properties of the closed-cell aluminum foam. In this work, a three-dimensional (3D) realistic structure was obtained by using the synchrotron X-ray micro-tomography technique and then translated into a numerical model for a further finite-element simulation. In order to investigate the early compressive deformation in the closed-cell aluminum foam, we chose three different strain levels, namely, 0.2% (initiation of plastic strain), 2.8% (propagation of plastic strain band), and 6% (formation of collapse band) to discuss the evolution forms of plastic strain concentration by simulation. We found that the curvature, anisotropy, and distribution of cell volume of adjacent cells played a vital role in the initiation of plastic strain. Furthermore, the phenomenon that plastic strain band propagated along the direction aligned 45° with respect to the orientation of the compression was also investigated in the propagation of the plastic strain band and formation of the collapse band. Finally, the comparison between experimental results and simulation results was performed to illustrate the early location of these three different levels in the whole compressive deformation.

A-242 Aluminium Alloy Foams Manufacture from the Recycling of Beverage Cans

This paper presents and discusses a methodology implemented to study the process of the preparation of aluminium alloy foams using the alloy A-242, beginning from the recycling of secondary aluminium obtained from beverage cans. The foams are prepared by a melting process by adding 0.50 wt.% calcium to the A-242 aluminium alloy with the aim to change its viscosity in the molten state. To obtain the foam, titanium hydride is added in different concentrations (0.50 wt.%, 0.75 wt.%, and 1.00 wt.%) and at different temperatures (923, 948 K, and 973 K) while the foaming time is kept constant at 30 s. For a set of experimental parameter values, aluminium alloy foams with the average relative density of 0.12 were obtained and had an 88.22% average porosity. In this way, it is possible to state that the preparation of aluminium alloy foams A-242 processed from the recycling of cans is possible, with characteristics and properties similar to those obtained using commercial-purity metals.

3D printed structures for modeling the Young's modulus of bamboo parenchyma

Bamboo is a sustainable, lightweight material that is widely used in structural applications. To fully develop micromechanical models for plants, such as bamboo, the mechanical properties of each individual type of tissue are needed. However, separating individual tissues and testing them mechanically is challenging. Here, we report an alternative approach in which micro X-ray computed tomography (µ-CT) is used to image moso bamboo (Phyllostachys pubescens). The acquired images, which correspond to the 3D structure of the parenchyma, are then transformed into physical, albeit larger scale, structures by 3D printing, and their mechanical properties are characterized. The normalized longitudinal Young's moduli of the fabricated structures depend on relative density raised to a power between 2 and 3, suggesting that elastic deformation of the parenchyma cellular structure involves considerable cell wall bending. The mechanical behavior of other biological tissues may also be elucidated using this approach.

STATEMENT OF SIGNIFICANCE

Bamboo is a lightweight, sustainable engineering material widely used in structural applications. By combining micro X-ray computed tomography and 3D printing, we have produced bamboo parenchyma mimics and characterized their stiffness. Using this approach, we gained insight into bamboo parenchyma tissue mechanics, specifically the cellular geometry's role in longitudinal elasticity.

A self-organising biomimetic collagen/nano-hydroxyapatite-glycosaminoglycan scaffold for spinal fusion

The use of spinal fusion surgery as a treatment for degenerative spinal conditions and chronic back pain is increasing. However, this technique requires use of a bone grafting material to fuse the vertebrae, traditionally autologous bone, which consists of an optimal combination of osteogenic cell precursors, extracellular matrix proteins and mineral components. To date, this remains the 'gold standard' material but its supply is limited and is associated with a number of clinical and ethical difficulties; consequently, various combinations of cells with biological scaffold materials have been tested but have failed to achieve fusion rates even comparable to autologous bone. We successfully fabricated a novel collagen-based scaffold using self-organising atelocollagen combined with nano-hydroxyapatite and chondroitin sulphate, cross-linked by microbial transglutaminase. The scaffold was characterised using a range of imaging, chemical composition and thermal analysis techniques. It was found to exhibit appropriate stiffness and suitable pore size for the adhesion, growth and differentiation of MSCs. The low toxicity makes it suitable for clinical application, and its slow degradation profile would enable the scaffold to promote bone growth over an extended period. This material therefore shows promise for clinical use in spinal fusion and other procedures requiring the use of bone grafts.

Effects of porosity on dynamic indentation resistance of silica nanofoam

The dynamic indentation behaviors of monolithic silica nanofoams of various porosities are investigated. When the pore size is on the nm scale, as the porosity increases, despite the decrease in mass density, the resistance offered by silica nanofoam to dynamic indentation is maintained at a high level, higher than the resistance of solid silica or regular porous silica. This phenomenon is related to the fast collapse of nanocells, which produces a locally hardened region and significantly increases the volume of material involved in impact energy dissipation.

Diametral compression behavior of biomedical titanium scaffolds with open, interconnected pores prepared with the space holder method

Scaffolds with open, interconnected pores and appropriate mechanical properties are required to provide mechanical support and to guide the formation and development of new tissue in bone tissue engineering. Since the mechanical properties of the scaffold tend to decrease with increasing porosity, a balance must be sought in order to meet these two conflicting requirements. In this research, open, interconnected pores and mechanical properties of biomedical titanium scaffolds prepared by using the space holder method were characterized. Micro-computed tomography (micro-CT) and permeability analysis were carried out to quantify the porous structures and ascertain the presence of open, interconnected pores in the scaffolds fabricated. Diametral compression (DC) tests were performed to generate stress-strain diagrams that could be used to determine the elastic moduli and yield strengths of the scaffolds. Deformation and failure mechanisms involved in the DC tests of the titanium scaffolds were examined. The results of micro-CT and permeability analyses confirmed the presence of open, interconnected pores in the titanium scaffolds with porosity over a range of 31-61%. Among these scaffolds, a maximum specific surface area could be achieved in the scaffold with a total porosity of 5-55%. DC tests showed that the titanium scaffolds with elastic moduli and yield strengths of 0.64-3.47GPa and 28.67-80MPa, respectively, could be achieved. By comprehensive consideration of specific surface area, permeability and mechanical properties, the titanium scaffolds with porosities in a range of 50-55% were recommended to be used in cancellous bone tissue engineering.

Controlled porosity and pore size of nano-porous gold by thermally assisted chemical dealloying – a SAXS study

Nano-porous metals offer great potential for applications such as bio-sensors, chemical reactors, platforms for cell growth, and media for separation because of their high surface area and reactivity at the nanoscale.

Fabrication of Aluminum Tubes Filled with Aluminum Alloy Foam by Friction Welding

Aluminum foam is usually used as the core of composite materials by combining it with dense materials, such as in Al foam core sandwich panels and Al-foam-filled tubes, owing to its low tensile and bending strengths. In this study, all-Al foam-filled tubes consisting of ADC12 Al-Si-Cu die-cast aluminum alloy foam and a dense A1050 commercially pure Al tube with metal bonding were fabricated by friction welding. First, it was found that the ADC12 precursor was firmly bonded throughout the inner wall of the A1050 tube without a gap between the precursor and the tube by friction welding. No deformation of the tube or foaming of the precursor was observed during the friction welding. Next, it was shown that by heat treatment of an ADC12-precursor-bonded A1050 tube, gases generated by the decomposition of the blowing agent expand the softened ADC12 to produce the ADC12 foam interior of the dense A1050 tube. A holding time during the foaming process of approximately t_H = 8.5 min with a holding temperature of 948 K was found to be suitable for obtaining a sound ADC12-foam-filled A1050 tube with sufficient foaming, almost uniform pore structures over the entire specimen, and no deformation and minimum reduction in the thickness of the tube.

Fabrication of Aluminum Foam-Filled Thin-Wall Steel Tube by Friction Welding and Its Compression Properties

Aluminum foam has received considerable attention in various fields and is expected to be used as an engineering material owing to its high energy absorption properties and light weight. To improve the mechanical properties of aluminum foam, combining it with dense tubes, such as aluminum foam-filled tubes, was considered necessary. In this study, an aluminum foam-filled steel tube, which consisted of ADC12 aluminum foam and a thin-wall steel tube, was successfully fabricated by friction welding. It was shown that a diffusion bonding layer with a thickness of approximately 10 μm was formed, indicating that strong bonding between the aluminum foam and the steel tube was realized. By the X-ray computed tomography observation of pore structures, the fabrication of an aluminum foam-filled tube with almost uniform pore structures over the entire specimen was confirmed. In addition, it was confirmed that the aluminum foam-filled steel tube exhibited mechanical properties superior to those of the ADC12 aluminum foam and steel tube. This is considered to be attributed to the combination of the aluminum foam and steel tube, which particularly prevents the brittle fracture and collapse of the ADC12 foam by the steel tube, along with the strong metal bonding between the aluminum foam and the steel tube.

Tensile Properties and Fracture Behavior of Aluminum Alloy Foam Fabricated from Die Castings without Using Blowing Agent by Friction Stir Processing Route

Al foam has been used in a wide range of applications owing to its light weight, high energy absorption and high sound insulation. One of the promising processes for fabricating Al foam involves the use of a foamable precursor. In this study, ADC12 Al foams with porosities of 67%–78% were fabricated from Al alloy die castings without using a blowing agent by the friction stir processing route. The pore structure and tensile properties of the ADC12 foams were investigated and compared with those of commercially available ALPORAS. From X-ray computed tomography (X-ray CT) observations of the pore structure of ADC12 foams, it was found that they have smaller pores with a narrower distribution than those in ALPORAS. Tensile tests on the ADC12 foams indicated that as their porosity increased, the tensile strength and tensile strain decreased, with strong relation between the porosity, tensile strength, and tensile strain. ADC12 foams exhibited brittle fracture, whereas ALPORAS exhibited ductile fracture, which is due to the nature of the Al alloy used as the base material of the foams. By image-based finite element (FE) analysis using X-ray CT images corresponding to the tensile tests on ADC12 foams, it was shown that the fracture path of ADC12 foams observed in tensile tests and the regions of high stress obtained from FE analysis correspond to each other. Therefore, it is considered that the fracture behavior of ADC12 foams in relation to their pore structure distribution can be investigated by image-based FE analysis.

Porous poly(para-phenylene) scaffolds for load-bearing orthopedic applications

The focus of this study was to fabricate and investigate the mechanical behavior of porous poly(para-phenylene) (PPP) for potential use as a load-bearing orthopedic biomaterial. PPPs are known to have exceptional mechanical properties due to their aromatic backbone; however, the manufacturing and properties of PPP porous structures have not been previously investigated. Tailored porous structures with either small (150-250µm) or large (420-500µm) pore sizes were manufactured using a powder-sintering/salt-leaching technique. Porosities were systematically varied using 50 to 90vol%. Micro-computed tomography (µCT) and scanning electron microscopy (SEM) were used to verify an open-cell structure and investigate pore morphology of the scaffolds. Uniaxial mechanical behavior of solid and porous PPP samples was characterized through tensile and compressive testing. Both modulus and strength decreased with increasing porosity and matched well with foam theory. Porous scaffolds showed a significant decrease in strain-to-failure (<4%) under tensile loading and experienced linear elasticity, plastic deformation, and densification under compressive loading. Over the size ranges tested, pore size did not significantly influence the mechanical behavior of the scaffolds on a consistent basis. These results are discussed in regards to use of porous PPP for orthopedic applications and a prototype porous interbody fusion cage is presented.

Graphene coating makes carbon nanotube aerogels superelastic and resistant to fatigue

Lightweight materials that are both highly compressible and resilient under large cyclic strains can be used in a variety of applications. Carbon nanotubes offer a combination of elasticity, mechanical resilience and low density, and these properties have been exploited in nanotube-based foams and aerogels. However, all nanotube-based foams and aerogels developed so far undergo structural collapse or significant plastic deformation with a reduction in compressive strength when they are subjected to cyclic strain. Here, we show that an inelastic aerogel made of single-walled carbon nanotubes can be transformed into a superelastic material by coating it with between one and five layers of graphene nanoplates. The graphene-coated aerogel exhibits no change in mechanical properties after more than 1 × 10(6) compressive cycles, and its original shape can be recovered quickly after compression release. Moreover, the coating does not affect the structural integrity of the nanotubes or the compressibility and porosity of the nanotube network. The coating also increases Young's modulus and energy storage modulus by a factor of ∼6, and the loss modulus by a factor of ∼3. We attribute the superelasticity and complete fatigue resistance to the graphene coating strengthening the existing crosslinking points or 'nodes' in the aerogel.

Higher recovery and better energy dissipation at faster strain rates in carbon nanotube bundles: an in-situ study

We report mechanical behavior and strain rate dependence of recoverability and energy dissipation in vertically aligned carbon nanotube (VACNT) bundles subjected to quasi-static uniaxial compression. We observe three distinct regimes in their stress-strain curves for all explored strain rates from 4 × 10(-2) down to 4 × 10(-4)/sec: (1) a short initial elastic section followed by (2) a sloped plateau with characteristic wavy features corresponding to buckle formation and (3) densification characterized by rapid stress increase. Load-unload cycles reveal a stiffer response and virtually 100% recoverability at faster strain rates of 0.04/sec, while the response is more compliant at slower rates, characterized by permanent localized buckling and significantly reduced recoverability. We propose that it is the kinetics of attractive adhesive interactions between the individual carbon nanotubes within the VACNT matrix that governs morphology evolution and ensuing recoverability. In addition, we report a 6-fold increase in elastic modulus and gradual decrease in recoverability (down to 50%) when VACNT bundles are unloaded from postdensification stage as compared with predensification. Finally, we demonstrate energy dissipation capability, as revealed by hysteresis in load-unload cycles. These findings, together with high thermal and electrical conductivities, position VACNTs in the "unattained-as-of-to-date-space" in the material property landscape.