Materials & DesignPub Date : 2025-07-28DOI: 10.1016/j.matdes.2025.114477
M.A. Wares , M.A. Kader , M.A. Islam , S. Ahmed
{"title":"Effects of artificial defects on the mechanical properties of additively manufactured gyroid unit cell","authors":"M.A. Wares , M.A. Kader , M.A. Islam , S. Ahmed","doi":"10.1016/j.matdes.2025.114477","DOIUrl":"10.1016/j.matdes.2025.114477","url":null,"abstract":"<div><div>Additive manufacturing has enabled the fabrication of complex geometries; however, the fabricated parts often contain a significant number of defects. In this study, we have introduced various types of artificial defects in the gyroid structure and explored their impact on the mechanical responses using finite element (FE) simulations. Three different pore shapes: spherical, ellipsoidal, and cubic are incorporated as defects at varying porosity levels to investigate their influence on collapse mechanisms and elastic properties. The FE model has been validated through the results obtained from quasi-static compression tests on defect-free and defective gyroids manufactured using fused deposition modeling. The results indicate that increasing porosity significantly reduces yield strength and elastic stiffness regardless of pore shape. However, the extent of stress inhomogeneity and plastic strain localization varies with pore shape, which leads to the variation of mechanical properties even at the same porosity levels. Gyroid structure with cubic porosity exhibits maximum stress inhomogeneity and plastic strain localization, resulting in the maximum reduction in yield strength and stiffness, followed by gyroid structure with ellipsoidal and spherical porosity. These findings provide insights into defect severity based on pore shape, enabling the improvement of additive manufacturing processes toward defect mitigation and enhanced mechanical performance.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"257 ","pages":"Article 114477"},"PeriodicalIF":7.9,"publicationDate":"2025-07-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144748694","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2025-07-28DOI: 10.1016/j.matdes.2025.114418
Jan Middelhoff, Klaus Dröder, André Hürkamp
{"title":"Machine learning approach for the prediction of forming results of fiber-reinforced thermoplastic composites using simulation and curvature data","authors":"Jan Middelhoff, Klaus Dröder, André Hürkamp","doi":"10.1016/j.matdes.2025.114418","DOIUrl":"10.1016/j.matdes.2025.114418","url":null,"abstract":"<div><div>Forming of fiber-reinforced thermoplastics is a promising process for the mass production of lightweight components. However, due to the complex material behavior, various types of defects may occur during forming, which affects component performance. The formation of wrinkles is the primary deformation phenomenon investigated in computational costly numerical forming simulations, typically by analyzing the shear angle distribution. Therefore, this contribution presents a machine learning-based approach using a convolutional autoencoder to predict the shear angle distribution of forming geometries. The approach leverages the curvature distribution of the geometry as input for the shear angle prediction, resulting in significantly reducing computation time compared to high-fidelity simulations. A database is developed based on the four principal curvatures (planar, parabolical, elliptical, hyperbolical) commonly found in forming geometries. Hyperparameter studies and the influence of database composition are investigated. Validation is conducted using an unseen, complex double dome geometry, followed by tests on additional geometries to evaluate model generalization. Results show that shear angle distributions can be accurately predicted using a simple curvature geometry database. The trained model thus enables rapid evaluation of forming behavior, accelerating the development process for fiber-reinforced thermoplastic components in thermoforming applications.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"257 ","pages":"Article 114418"},"PeriodicalIF":7.9,"publicationDate":"2025-07-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144724348","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2025-07-26DOI: 10.1016/j.matdes.2025.114464
Mubasher Ali , Uzair Sajjad , Ahsan Ali , Hafiz Muhammad Ali , Khalid Hamid
{"title":"Metallic nanoparticles-based additive manufacturing: A review of recent advances on progress, prospects, and challenges","authors":"Mubasher Ali , Uzair Sajjad , Ahsan Ali , Hafiz Muhammad Ali , Khalid Hamid","doi":"10.1016/j.matdes.2025.114464","DOIUrl":"10.1016/j.matdes.2025.114464","url":null,"abstract":"<div><div>This review comprehensively examines the integration of metallic nanoparticles (MNPs) into additive manufacturing (AM) technologies, highlighting how this fusion advances material properties and process capabilities. The key advancements achieved by incorporating MNPs in AM processes, such as improved mechanical strength, enhanced thermal and electrical conductivity, and increased corrosion resistance, are also outlined in this review. Various methods for incorporating MNPs into AM processes, such as blending with metal powders for powder bed fusion, mixing with polymers in ink formulations for inkjet printing, surface coating techniques, etc., are also categorized in this review. It also explores the practical challenges faced in this integration, including achieving homogeneous MNPs distribution, managing increased production costs, and scaling the technology for large-scale applications. Additionally, the review highlights diverse applications across industries such as aerospace, where enhanced strength and thermal management are crucial; biomedical fields, where improved biocompatibility and functionality are vital; and electronics, where enhanced conductivity and miniaturization are beneficial. By summarizing current advancements, identifying research gaps, and proposing future research directions, this review provides a thorough understanding of how MNPs can be leveraged to revolutionize AM and its applications.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"257 ","pages":"Article 114464"},"PeriodicalIF":7.9,"publicationDate":"2025-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144721883","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2025-07-26DOI: 10.1016/j.matdes.2025.114474
Tao Xi Wang , Ming Jun Gao , Ting Xuan Jordon Neo , Xuan Qi Amos Lim , Jun Hong Ng , Hong Mei Chen , Hu Wei Bian , Xing Shen , Wei Min Huang , Tao Jiang
{"title":"Rapid water-triggered hardening of ethanol-softened shape memory polyurethane for shape fixation and minimally invasive biomedical applications","authors":"Tao Xi Wang , Ming Jun Gao , Ting Xuan Jordon Neo , Xuan Qi Amos Lim , Jun Hong Ng , Hong Mei Chen , Hu Wei Bian , Xing Shen , Wei Min Huang , Tao Jiang","doi":"10.1016/j.matdes.2025.114474","DOIUrl":"10.1016/j.matdes.2025.114474","url":null,"abstract":"<div><div>This study presents a rapid water-triggered hardening strategy for ethanol-softened shape memory polyurethanes (SMPU), including thermoset foams and thermoplastic polyurethane (TPU) films/membranes. The SMPU foam, once softened by 70 % ethanol, becomes highly compressible for minimally invasive delivery. Subsequent immersion in water effectively removes ethanol and restores mechanical stiffness of the foam within minutes, with the Young’s modulus increasing from 0.001 MPa (softened state) to over 0.8 MPa after 5 min—far surpassing air drying alone. This ethanol–water exchange mechanism enables shape fixation without the need for thermal activation or toxic solvents. The concept is further validated in TPU films and electrospun membranes, which exhibit localized and programmable shape recovery under similar treatment. In vascular phantom models, the SMPU foam demonstrates conformal filling of aneurysmal geometries with secure fixation post-hardening. These findings suggest a solvent-responsive, biocompatible platform suitable for embolization and other minimally invasive biomedical applications, offering a safer and faster alternative to traditional shape memory approaches.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"257 ","pages":"Article 114474"},"PeriodicalIF":7.6,"publicationDate":"2025-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144714431","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2025-07-25DOI: 10.1016/j.matdes.2025.114463
Jana Harbig , Holger Merschroth , Matthias Greiner , Philipp Drossel , Christian Mittelstedt , Matthias Weigold
{"title":"Homogenization of the melt pool influenced by the local transient thermal conditions using model-based parameter adaption in powder bed fusion","authors":"Jana Harbig , Holger Merschroth , Matthias Greiner , Philipp Drossel , Christian Mittelstedt , Matthias Weigold","doi":"10.1016/j.matdes.2025.114463","DOIUrl":"10.1016/j.matdes.2025.114463","url":null,"abstract":"<div><div>Powder Bed Fusion with Laser Beam and Metal (PBF-LB/M) is being increasingly applied in a wide range of industries. The manufacturing process enables an increased lightweight construction potential, an extreme individualization potential and functional integration across all industries. However, a wide range of process influences cause an inhomogeneous process and therefore inhomogeneous properties of the manufactured component. This leads to defects or reduced mechanical properties. One process influence is the scanning strategy, which defines the pattern in the laser scan. Currently used scanning strategies lead to different cooling times of the neighbour melt track when the laser is at a similar position. This leads to local transient thermal conditions. Investigations in this paper show an increase in the melt pool size of 238 %. Therefore, two methods for describing and homogenizing the influence of the local transient thermal conditions on the melt pool are presented. A dimensionless number for predicting and homogenizing the local melt pool geometry is developed. Secondly, a method for local thermal homogenization using process monitoring systems is presented. Process homogenization is achieved by adjusting the laser power. The influence of local transient thermal conditions on the melt pool is reduced by up to 86.8 %.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"257 ","pages":"Article 114463"},"PeriodicalIF":7.9,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144748814","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2025-07-24DOI: 10.1016/j.matdes.2025.114460
Y. Ben Jedidia, S.P. Murugan, X. Feaugas, A. Oudriss
{"title":"Study of the anisotropic effects of hydrogen on the subsurface mechanical behavior of nickel single crystal by nanoindentation","authors":"Y. Ben Jedidia, S.P. Murugan, X. Feaugas, A. Oudriss","doi":"10.1016/j.matdes.2025.114460","DOIUrl":"10.1016/j.matdes.2025.114460","url":null,"abstract":"<div><div>Hydrogen ingress can significantly alter subsurface mechanical properties, often in a different manner than in the bulk. In this work, we investigate the effect of hydrogen on the subsurface mechanical behavior of face-centered cubic nickel single crystals using nanoindentation. Four crystallographic orientations (100), (110), (111), and (219) were examined before and after electrochemical hydrogen charging, with particular attention paid to surface preparation. The mechanical response is analyzed in terms of the nanoindentation reduced modulus (using the Hertz model), pop-in load and depth, and hardness. Our results show a reduction in elastic modulus that depends on crystallographic orientation and is associated with vacancy formation and potential hydride phases. Hydrogen alters the anisotropy of incipient plasticity through elastic shielding and enhanced dislocation pinning. The observed trends, orientation-dependent softening of modulus, depth-dependent pop-in behavior, and changes in critical shear stress are explained by the competing effects of softening (via vacancy and hydride formation) and hardening (via dislocation pinning), thus offering new insights into hydrogen-induced mechanical anisotropy in nickel.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"257 ","pages":"Article 114460"},"PeriodicalIF":7.9,"publicationDate":"2025-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144721675","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2025-07-24DOI: 10.1016/j.matdes.2025.114465
Danrong Shi, Zhuangzhuang Wang, Yongwei Li, Ruyuan Huo, Jin Zhang, Jianguo Cai
{"title":"A novel re-entrant circular star-shaped auxetic honeycomb with enhanced energy absorption and anisotropic Poisson’s ratio","authors":"Danrong Shi, Zhuangzhuang Wang, Yongwei Li, Ruyuan Huo, Jin Zhang, Jianguo Cai","doi":"10.1016/j.matdes.2025.114465","DOIUrl":"10.1016/j.matdes.2025.114465","url":null,"abstract":"<div><div>Traditional auxetic honeycomb structures often exhibit limited energy absorption capacity, particularly under large deformation conditions. This study proposes an anisotropic auxetic configuration—the re-entrant circular star-shaped honeycomb (RECSH)—to enhance energy absorption and reduce initial peak force. A comprehensive investigation involving experimental testing, theoretical modelling, and finite element (FE) simulations was carried out to evaluate the in-plane quasi-static compressive behaviour of RECSH. The results revealed a two-plateau deformation response, each of which exhibited a distinct stress plateau attributed to the structural support provided by the embedded circular geometry. A theoretical framework based on plastic dissipation was developed to predict the plateau stresses, and the influence of key geometric parameters on deformation modes and energy absorption was systematically examined. A multi-objective optimisation strategy was used by a Kriging surrogate model and NSGA-II algorithm to identify an optimal configuration with improved crashworthiness. Compared with conventional designs, the optimised RECSH demonstrates enhanced specific energy absorption (SEA) and reduces initial peak stress (IPS) in both <em>x</em>- and <em>y</em>-directions. This novel auxetic structure offers promising potential for applications in impact mitigation and crash protection systems.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"257 ","pages":"Article 114465"},"PeriodicalIF":7.9,"publicationDate":"2025-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144724349","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Temperature-dependent mechanism on hardening mitigation in thermomechanically processed 800H alloys under neutron irradiation","authors":"Weicheng Zhong , Yaqiao Wu , Xiang (Frank) Chen , Lizhen Tan","doi":"10.1016/j.matdes.2025.114430","DOIUrl":"10.1016/j.matdes.2025.114430","url":null,"abstract":"<div><div>Irradiation induced hardening is commonly observed in structural materials, and is often associated with the degraded ductility. This study explores the role of thermomechanical processing (TMP) in mitigating irradiation-induced hardening in Incoloy 800H. The radiation response of solution-annealed and TMP-treated samples was systematically investigated to elucidate the underlying mechanisms of hardening reduction. Neutron irradiation was performed on solution-annealed and TMP-treated samples at 359, 431, and 580 °C, revealing consistently lower hardening in TMP samples. Microstructural characterization compared dislocation loops, cavities, clusters, and precipitates to assess their contributions to hardening. The strengthening contributions from individual microstructural features were estimated, and the microstructure-derived yield strength is consistent with the hardness-converted yield strength. The microstructure–properties correlation revealed the temperature-dependent primary hardening mechanism: dislocation loops dominated at lower temperature, whereas Ni<sub>3</sub>(Al,Ti) γ′ precipitates were predominant at higher temperature. TMP reduced radiation-induced hardening through two mechanisms: (1) increased sink strength from dislocations and Ti(C,N) precipitates limited dislocation loop formation at lower temperatures, and (2) reduced Ti solute within the matrix in TMP samples suppressed γ′ precipitate formation at higher temperatures. These findings identify the mechanisms governing radiation-induced hardening across different temperatures, which lays the foundation for TMP optimization for the development of advanced radiation-tolerant materials.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"257 ","pages":"Article 114430"},"PeriodicalIF":7.9,"publicationDate":"2025-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144724347","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2025-07-24DOI: 10.1016/j.matdes.2025.114467
Zhuo Chen , Huitian Wang , Zihan Hu , Limin Zhou , Yiu Wing Mai , Robert O. Ritchie , Sha Yin
{"title":"Nature-inspired heterogeneous metamaterials: functional design framework","authors":"Zhuo Chen , Huitian Wang , Zihan Hu , Limin Zhou , Yiu Wing Mai , Robert O. Ritchie , Sha Yin","doi":"10.1016/j.matdes.2025.114467","DOIUrl":"10.1016/j.matdes.2025.114467","url":null,"abstract":"<div><div>Heterogeneous mechanical metamaterials can achieve extraordinary properties through their complex and diverse microstructural designs. However, research on the functional realization by heterogeneous mechanical metamaterials in varying scenarios remains insufficient. Nature’s materials generally feature irregular and multi-material characteristics, endowing them with remarkable functions such as mechanical stress regulation and crush protection. Accordingly, herein, we combine these two features to create a unified framework for the design of heterogeneous mechanical metamaterials. By optimizing the spatial distribution of a limited set of unit cells, we show that irregular and multi-material metamaterials can be assembled to achieve functions such as cloak, protection, and field control characteristics, demonstrating the universality of this framework. Although our optimized structures are irregular and non-periodic, the assembled materials exhibit spatially varying characteristics, allowing precise displacement or stress distribution adjustment in different control regions under various loading conditions to achieve functionality. Our approach excels in rapidly responding to new design scenarios that offer inspiration for the efficient design of functional metamaterials.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"257 ","pages":"Article 114467"},"PeriodicalIF":7.9,"publicationDate":"2025-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144721884","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2025-07-24DOI: 10.1016/j.matdes.2025.114468
Yuan Zhang , Ruinan Wang , Hengping Wang , Haiming Cheng , Huiyan Wang
{"title":"Herbal hydrogel incorporating Scutellaria baicalensis Georgi carbon dots and baicalein for antibacterial, anti-inflammatory, and wound healing applications","authors":"Yuan Zhang , Ruinan Wang , Hengping Wang , Haiming Cheng , Huiyan Wang","doi":"10.1016/j.matdes.2025.114468","DOIUrl":"10.1016/j.matdes.2025.114468","url":null,"abstract":"<div><div>Wound infection and excessive accumulation of reactive oxygen species (ROS) lead to inflammation, hindering wound healing. Baicalein (BAI) and baicalin (BA) coexist in <em>Scutellaria baicalensis Georgi</em>, with baicalein being one of the most abundant flavonoids in the plant. In this study, carbon dots (CDs) were hydrothermally synthesized from <em>Scutellaria baicalensis Georgi</em> leaves and incorporated with baicalein (BAI) into a sodium alginate hydrogel to form BCG hydrogel. BCG exhibited ROS scavenging activity and promoted NIH/3T3 cell proliferation and migration under oxidative stress, while also demonstrating in vitro antibacterial activity against <em>E. coli</em> and <em>S. aureus</em>. In an infected wound model, the wound area treated with BCG was reduced to only 2 % by the 8th day. The wound area shows marked anti-inflammatory and pro-angiogenic effects, evidenced by activation of the Nrf2 antioxidant pathway, suppression of NF-κB signaling, reduced inflammation, and enhanced neovascularization. In conclusion, this study provides a strategy for the comprehensive utilization of the entire <em>Scutellaria baicalensis Georgi</em> plant and reveals promising prospects for the combined use of herbal medicines and non-medicinal parts as an effective approach for chronic wound healing.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"257 ","pages":"Article 114468"},"PeriodicalIF":7.6,"publicationDate":"2025-07-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144711380","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}