P.F. Nogueira, J.P. Magrinho, P.A.F. Martins, M.B. Silva
{"title":"A volume ratio method for determining the onset of yielding in lattice structures","authors":"P.F. Nogueira, J.P. Magrinho, P.A.F. Martins, M.B. Silva","doi":"10.1016/j.ijlmm.2025.12.009","DOIUrl":"10.1016/j.ijlmm.2025.12.009","url":null,"abstract":"<div><div>This paper introduces a novel method for determining the yield stress of lattice structural materials fabricated through metal additive manufacturing (MAM). The new method, named the ‘volume ratio method’, defines yielding based on a threshold volume fraction of the lattice material that has undergone plastic deformation. The volume ratio method is applied to multiple finite element lattice models with five distinct unit cell geometries and across a broad range of relative densities. The finite element simulations employ experimentally calibrated material properties for pure iron, and the results are compared to the traditional 0.2 % offset method. Results show that the 0.2 % offset method often fails to accurately capture the early onset of plastic deformation, leading to an overestimation of yield stress values by as much as 78.6 %, primarily due to geometric nonlinearity and localized stress fields inherent in lattice structures. In contrast, the volume ratio method provides earlier detection of plasticity, accurately reflecting the heterogeneous stress distribution typical of these structures. Overall, the volume ratio method offers a practical, intuitive, and computationally feasible alternative for accurately identifying the yield point in lattice structural material produced by MAM, thereby enhancing design reliability in applications where premature plasticity is a critical concern.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 4","pages":"Pages 498-509"},"PeriodicalIF":6.9,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148546165","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Thermal deformation behaviour and physically-based dual-phase constitutive model of Ni/Ni2Al3 laminated composites","authors":"Pengxiao Yang, Mengmeng Li, Zhou Wan, Yaping Wang, Bao Wang, Jingwei Xian, Peng Lin, Kailun Zheng","doi":"10.1016/j.ijlmm.2026.01.002","DOIUrl":"10.1016/j.ijlmm.2026.01.002","url":null,"abstract":"<div><div>To investigate the high-temperature deformation behaviour of Ni/Ni<sub>2</sub>Al<sub>3</sub> laminated composites with greater precision, a series of uniaxial tensile experiments was conducted at 700 °C under various strain rates of 0.001 s<sup>−1</sup>, 0.002 s<sup>−1</sup>, 0.005 s<sup>−1</sup>, and 0.01 s<sup>−1</sup> to obtain the evolution of flow stress and fracture elongation. Experimental results indicated that the material exhibited uniform deformation and superplastic deformation behaviour under high-temperature loading conditions. With an increase of strain rate from 0.001 s<sup>−1</sup> to 0.01 s<sup>−1</sup>, the elongation of fractures exhibited a gradual tendency of decreasing from a peak of 249.5 %, with an increasing tendency of the highest flow stress from 85.4 MPa to 147.3 MPa. To elucidate the microstructural evolution during deformation, scanning electron microscopy and electron backscatter diffraction were conducted on specimens to examine the microstructural evolution before and after deformation. These characterisations demonstrated that dynamic recrystallisation and dislocation pile-up occurred concurrently in both Ni and Ni<sub>2</sub>Al<sub>3</sub> phases during the high-temperature deformation process. A dual-phase viscoplastic constitutive model was developed based on macroscopic and microscopic experimental data, incorporating the evolution of physically-based internal state variables. The model successfully predicted the high-temperature stress-strain behaviour of the Ni/Ni<sub>2</sub>Al<sub>3</sub> laminated composites, achieving a prediction accuracy of 98.79 %. Moreover, the model accurately predicted the grain size evolution within individual phases, offering a mechanistic insight into the deformation response of each constituent phase. The proposed modelling framework provides a robust theoretical basis for optimising thermal-mechanical processing and the numerical simulation of Ni–Al intermetallic composites. Beyond the present analysis, the methodology can be adapted to construct predictive models of Ni–Al intermetallic composites tested at 700 °C with different strain rates, providing the quantitative evaluation of mechanical performance and dual-phase microstructural evolution during the high-temperature manufacturing process.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 4","pages":"Pages 521-537"},"PeriodicalIF":6.9,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148546163","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Energy absorption characterization of tubes filled with auxetic and non-auxetic lattice structures under lateral loading","authors":"Tom Ingram, Kadir Gunaydin, Zafer Kazancı","doi":"10.1016/j.ijlmm.2025.12.006","DOIUrl":"10.1016/j.ijlmm.2025.12.006","url":null,"abstract":"<div><div>This study examines the energy absorption performance of aluminium crash tubes under lateral compression, focusing on the effect of internal lattice fillers. Tubes were tested in both empty and filled configurations, with three distinct lattice designs: re-entrant and double arrowhead auxetic structures, and a conventional non-auxetic honeycomb, which served as a reference. The lattices were fabricated from polycarbonate via fused filament fabrication (FFF). Quasi-static compression tests were conducted to evaluate key crashworthiness metrics, including energy absorption (EA), specific energy absorption (SEA), peak force (P<sub>max</sub>), mean crush force (MCF), and crush force efficiency (CFE). Finite element simulations were performed and validated against experimental data. Results demonstrate that lattice-filled tubes significantly outperformed empty tubes, with SEA enhancements ranging from 55% to 255%, depending on the lattice geometry. Notably, the non-auxetic honeycomb lattice achieved the highest EA, SEA, MCF, and CFE values, primarily due to its thicker cell walls and associated structural stiffness. These findings highlight the potential of engineered lattice fillers to enhance the crashworthiness of tubular structures under lateral loading.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 4","pages":"Pages 469-483"},"PeriodicalIF":6.9,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148546229","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Mahdi Yeganeh, Jader Malehi Zadeh, Seyed Reza Alavi Zaree, Mehdi Khorasanian, Hafiz Muhammad Rehan Tariq, Dain Choi, Hyun-Hak Kang, Tea-Sung Jun
{"title":"Effect of volumetric energy density on the microstructure, mechanical, corrosion, and biological behavior of Ti–Cu alloy manufactured by laser powder bed fusion","authors":"Mahdi Yeganeh, Jader Malehi Zadeh, Seyed Reza Alavi Zaree, Mehdi Khorasanian, Hafiz Muhammad Rehan Tariq, Dain Choi, Hyun-Hak Kang, Tea-Sung Jun","doi":"10.1016/j.ijlmm.2025.12.008","DOIUrl":"10.1016/j.ijlmm.2025.12.008","url":null,"abstract":"<div><div>This study investigates the influence of volumetric energy density (<em>VED</em>) on the microstructural evolution, mechanical behavior, corrosion resistance, and biological performance of Ti–10Cu alloys fabricated via laser powder bed fusion (LPBF). Varying <em>VED</em> significantly affects the formation and distribution of Ti<sub>2</sub>Cu intermetallic phases and α′-martensite refinement in the as-built microstructure. Results show that higher <em>VED</em> promotes better copper dissolution, enhanced formation of TiCu intermetallic, and refined α′-Ti laths, resulting in improved hardness. Electrochemical testing in phosphate-buffered saline (PBS) reveals that moderate <em>VED</em> yields optimal corrosion resistance, while excessive TiCu formation at high <em>VED</em> may trigger micro-galvanic corrosion. Antibacterial disk diffusion and MTT assays confirm that Ti–10Cu samples exhibit strong bactericidal activity against <em>E. coli</em>, with A2 and A3 samples showing significant antibacterial zones. Importantly, all samples maintain acceptable cytocompatibility, with A2 offering the best balance between antimicrobial performance and cell viability. This work establishes a clear process–structure–property–performance relationship for LPBF Ti–10Cu and provides guidance for tuning <em>VED</em> to optimize functional outcomes in biomedical applications.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 4","pages":"Pages 484-497"},"PeriodicalIF":6.9,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148546164","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
John Millar, David Alonso-Caneiro, Umer Izhar, Damon Kent
{"title":"Geometry and constraint dependent energy absorption and mechanical responses of finite elastomeric 3D-printed auxetic structures","authors":"John Millar, David Alonso-Caneiro, Umer Izhar, Damon Kent","doi":"10.1016/j.ijlmm.2025.12.005","DOIUrl":"10.1016/j.ijlmm.2025.12.005","url":null,"abstract":"<div><div>Auxetic structures, characterised by negative Poisson’s ratios, exhibit exceptional energy absorption and controlled deformation making them ideal for applications in soft robotics, wearable sensors, biomedical devices, and structural monitoring. This study investigates the mechanical behaviour of novel hybrid re-entrant chiral geometry structures utilising re-entrant arms that facilitate chiral rotation during deformation. The hybrid re-entrant chiral auxetic structures fabricated from thermoplastic polyurethane, focusing on influence of geometric aspect ratio and boundary constraints on the compression deformation responses. Small-scale finite 2 × 2 cell array auxetic structures were investigated to provide insights into edge-dominated deformation responses critical to structures with constrained dimensions such as wearable sensors and soft robotics. Five structural variants with constant material volume and aspect ratios ranging from 0.83 to 1.33 were fabricated by fused deposition modelling. Compression testing and structural modelling revealed substantial dependence of the mechanical properties, including stiffness, buckling, and energy absorption, on the aspect ratio and boundary conditions. The lowest aspect ratio (0.83) structure maintained linear elasticity to 1.25 % strain without constraint, reducing to 0.50 % with constraint. Conversely, the highest aspect ratio (1.33) structure had reduced elastic strain capacity (0.30 %) due to more prominent axial stiffening. Constrained specimens had higher initial stiffness, increasing from 6 kPa to 14.1 kPa as aspect ratio was increased from 0.83 to 1.33, while equivalent counterparts without boundary constraints ranged from 2.8 kPa to 8.7 kPa. For lower aspect ratio designs, the specific energy absorption was up to 180 % higher at 30 % strain with the constraints. Energy absorption was diminished for higher aspect ratio designs due to greater influence of geometric stiffening. The findings provide new insights into coupled effects from geometry and constraints on mechanical responses to guide design of auxetic structures for small-scale flexible load-bearing devices.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 4","pages":"Pages 454-468"},"PeriodicalIF":6.9,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148546117","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
J.P. Magrinho, M.F. Ferreira, P.A.F. Martins, M.B. Silva
{"title":"Injection forging of thin-walled tubes","authors":"J.P. Magrinho, M.F. Ferreira, P.A.F. Martins, M.B. Silva","doi":"10.1016/j.ijlmm.2025.07.001","DOIUrl":"10.1016/j.ijlmm.2025.07.001","url":null,"abstract":"<div><div>This paper presents an innovative injection forging process designed for the manufacturing of net-shape thin-walled tubular components with integrated functional features. The research combines finite element modelling with the design and construction of a modular, flexible injection forging tool, allowing for efficient production in small batch sizes. Experiments conducted on thin-walled aluminium tubes demonstrate the feasibility and effectiveness of this new concept, showcasing the successful formation of external annular flanges with a flange width-to-tube thickness ratio of 0.46. This new process enables the production of flanges with improved structural performance by eliminating the need for secondary joining or machining operations. Additionally, the new injection forging process promotes advancements in sustainable manufacturing by offering a cost-effective way to fabricate lightweight complex tubular parts while addressing current industry challenges related to efficiency and material utilization.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 4","pages":"Pages 430-439"},"PeriodicalIF":6.9,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148546167","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Experimental surface modification, prediction modeling, and multi-objective optimization of μ-EDM process using GBR-NSGA-II for machining of Ti-6Al-4V+8%Ta","authors":"Shahid Ali, Altair Kossymbayev, Dinmukhammed Kenesbek, Dulat Yeregenov, Didier Talamona, Asma Perveen","doi":"10.1016/j.ijlmm.2025.12.004","DOIUrl":"10.1016/j.ijlmm.2025.12.004","url":null,"abstract":"<div><div>Metal 3D printing offers a promising solution for producing customized Ti-alloy components. However, due to inherent process limitations, additional post-processing is required for the fabrication of micro-features. Therefore, precision machining techniques like micro-EDM are still required. Micro-EDM is an advanced machining technique better known for its precision while machining titanium alloys. Even though the μ-EDM provides superior performance; however, the optimization of its machining parameters remains a significant challenge due to the complex interactions between electrical and thermal phenomena. Thus, the present research aimed at optimizing the parameters for μ-EDM machining of the SLM-printed Ti-6Al-4V + 8%Ta. A data-driven hybrid optimization framework combining GBR and the NSGA-II is developed to enhance the machinability of the alloy. The GBR models accurately predicted MRR, OC, and MH, achieving R<sup>2</sup> values of 0.987 (MRR), 0.999 (MH), and 0.999 (OC), with correspondingly low MAE and MSE values across training and testing datasets. Whereas the TWR has shown a low R<sup>2</sup> (>75 %) value, which can be attributed to the inherent stochasticity. Additionally, the study is structured within a multi-objective optimization framework, emphasizing the maximization of MRR and MH while minimizing OC and TWR. After obtaining the possible number of optimal solutions from the surrogate model, the top five solutions are selected using TOPSIS. Lastly, confirmatory experiments validated the framework, showing MAPE deviations of less than ∼13.96 % between predicted and experimental results. This integrated methodology effectively navigates the multifaceted nature of μ-EDM parameter optimization.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 4","pages":"Pages 440-453"},"PeriodicalIF":6.9,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148546168","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Markos Petousis, Nikolaos Mountakis, Nikolaos Michailidis, Amalia Moutsopoulou, Maria Spyridaki, Katerina Gkagkanatsiou, Ioannis Valsamos, Emmanuel Stratakis, Nectarios Vidakis
{"title":"Sensitivity index and strain rate dependent metrics of lightweight acrylonitrile styrene acrylate (ASA) in MEX additive manufacturing","authors":"Markos Petousis, Nikolaos Mountakis, Nikolaos Michailidis, Amalia Moutsopoulou, Maria Spyridaki, Katerina Gkagkanatsiou, Ioannis Valsamos, Emmanuel Stratakis, Nectarios Vidakis","doi":"10.1016/j.ijlmm.2026.01.001","DOIUrl":"10.1016/j.ijlmm.2026.01.001","url":null,"abstract":"<div><div>The properties of acrylonitrile styrene acrylate (ASA) are similar to acrylonitrile butadiene styrene. However, it is more robust against environmental phenomena. Therefore, it is capable of use in outdoor applications. Its behavior under different strain rates in 3D printing is still insufficiently investigated. The aim herein was to report the 3D printed ASA parts' mechanical performance for test speeds varying from 10 to 300 mm/s. The mechanical performance is affected by the viscoelastic behavior of the material and the 3D printing structure. ASA was sourced in raw form. It was then extruded into filament and finally into tensile specimens. Thermal examinations included thermogravimetric analysis and differential scanning calorimetry. Scanning electron microscopy on the lateral and fractured surfaces contributed to the samples' morphological evaluation. The ultimate strength, yield strength, stiffness, and toughness were assessed from the performed tensile experiments. To investigate the material’s deformation mechanisms, the strain rate sensitivity index m was determined. The samples subjected to higher strain rates had higher strength (∼47 MPa, compared to 41 MPa at the standard test speed, ∼13 % increase), stiffness (∼510 MPa, compared to ∼470 MPa at the standard test speed, ∼8 % increase), and toughness (∼7.42 MJ/m<sup>3</sup> at 250 mm/min, compared to ∼4.67 MJ/m<sup>3</sup> at 75 mm/min, ∼37 % increase). Toughness was higher at low and high strain rates and lower at median values. Ductility increased at higher strain rates, contributing to the toughness increase. The strain rate sensitivity index was higher at low speeds (∼0.06 at 75 mm/min, compared to ∼0.018 at 250 mm/min). Samples were more brittle at medium strain rates. These findings provide valuable information for the design of ASA 3D printed components operating under high-speed loads.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 4","pages":"Pages 510-520"},"PeriodicalIF":6.9,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148546118","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Oleg Shamilevich Sitdikov, Elena Viktorovna Avtokratova, Rinat Rustemovich Zagitov, Oksana Eduardovna Latypova, Stanislav Vatslavovich Krymskiy, Mikhail Vyacheslavovich Markushev
{"title":"Microstructure and mechanical properties of multidirectionally forged Al alloy 1570С subjected to cryogenic rolling","authors":"Oleg Shamilevich Sitdikov, Elena Viktorovna Avtokratova, Rinat Rustemovich Zagitov, Oksana Eduardovna Latypova, Stanislav Vatslavovich Krymskiy, Mikhail Vyacheslavovich Markushev","doi":"10.1016/j.ijlmm.2025.03.005","DOIUrl":"10.1016/j.ijlmm.2025.03.005","url":null,"abstract":"<div><div>The effect of cryogenic rolling at −196 °C up to 90 % reduction on the microstructure and static strength of a 1570C alloy (Al–5.0Mg–0.18Mn–0.2Sc–0.08Zr–0.01Fe–0.01Si wt%), pre-processed by multidirectional isothermal forging (MIF) at 325 °C to a total strain of about 12, is investigated. MIF of the homogenized ingot allowed to obtain a near-homogeneous (ultra)fine grained (UFG) structure with a grain size of 2.3 μm, leveled Mg in solid solution and a uniform distribution of second phases, which ensured subsequent rolling without cracking. Rolling transformed the forged structure into a pancaked (flattened) UFG high work-hardened structure with a halved fraction of high-angle boundaries, characterized by a dislocation density of 10<sup>15</sup> m<sup>−2</sup> and a partially developed nano-sized crystallite structure with a coherent domain size of 15 nm. These structural changes resulted in significant improvements in room temperature tensile strength compared to the initial homogenized/forged conditions: yield strength increased from 245/235 to 590 MPa and ultimate tensile strength increased from 355/365 to 620 MPa, while elongation decreased from 26/37 to 9 %. The increase in strength with reduced ductility is attributed to the superposition of grain boundary and dislocation strengthening mechanisms amid dispersion strengthening. Therewith, cryogenic rolling promotes uniform dislocation structures and a homogeneous distribution of Al<sub>3</sub>(Sc,Zr) precipitates, which interact with the dislocations to maintain relatively high ductility even in a highly deformed state.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"9 4","pages":"Pages 413-429"},"PeriodicalIF":6.9,"publicationDate":"2026-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148546166","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}