E. Devine, M. Lester, T. McElroy, T. Valenzuela, W. LePage
{"title":"Mechanical Characterization of Additive-Manufactured Ti-6Al-4V Processed via Bound Metal Deposition","authors":"E. Devine, M. Lester, T. McElroy, T. Valenzuela, W. LePage","doi":"10.1007/s11340-025-01178-x","DOIUrl":"10.1007/s11340-025-01178-x","url":null,"abstract":"<div><h3>Background</h3><p>Additive manufacturing (AM) is rapidly growing, with new AM methods continually in development. Alloys processed with novel methods require systematic characterization to understand and validate the materials, especially for demanding fields.</p><h3>Objective</h3><p>This study characterized the mechanical properties and failure mechanisms of a Ti-6Al-4V alloy manufactured with bound metal deposition (BMD), a form of metal extrusion (MEX) AM.</p><h3>Methods</h3><p>Specimens made of Ti64 were printed via Desktop Metal’s Studio System 2 through a printing, debinding, and sintering process. The microstructure was analyzed with optical metallography and a newly developed open-source porosity analysis tool. Scanning electron microscopy (SEM), optical microscopy, and compositional analysis of green, brown, and sintered parts were conducted to study the material and its failure modes. Sintered specimens were tensile and hardness tested.</p><h3>Results</h3><p>As-sintered specimens exhibited ductility more than 10 times lower than wrought Ti64, partially due to contamination/impurity that formed brittle <span>(alpha )</span>-case titanium. Sources of contamination may have included the sacrificial Al<span>(_2)</span>O<span>(_3)</span> interlayer, the wax/polymer binder, and/or impurity introduction from the furnace. Fractography imaging found quasi-cleavage fracture initiating at areas of high surface roughness along the ceramic interlayer surface of the parts and transitioning into dimple rupture and intergranular decohesion.</p><h3>Conclusions</h3><p>Elevated contamination levels, high surface roughness, and internal porosity led to low elongation and ultimate strength in the Ti64 BMD alloy. With the processing route presented here, BMD for Ti64 may not be suitable for applications that demand high ductility and strength with minimal impurities, although with process refinement, the method may be promising for certain applications</p></div>","PeriodicalId":552,"journal":{"name":"Experimental Mechanics","volume":"65 4","pages":"573 - 596"},"PeriodicalIF":2.0,"publicationDate":"2025-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919006","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
D. Hertz-Eichenrode, H. Talebinezhad, A. Shmatok, R.D. Fischer, S. Bremen, W. Reichert, B.C. Prorok
{"title":"4D Porosity Evolution in Additively Manufactured 316L Stainless Steel through In-Situ Tensile Testing and X-Ray Computed Tomography","authors":"D. Hertz-Eichenrode, H. Talebinezhad, A. Shmatok, R.D. Fischer, S. Bremen, W. Reichert, B.C. Prorok","doi":"10.1007/s11340-025-01180-3","DOIUrl":"10.1007/s11340-025-01180-3","url":null,"abstract":"<div><h3>Background</h3><p>Many aspects of ductile failure through microvoid coalescence remain elusive due to the challenging spatial and temporal scales it operates on. Experimentally resolving all aspects of the process remains a significant goal of researchers. Much of the current understanding has been derived from post-mortem metallography, leaving key aspects of its evolution undocumented.</p><h3>Objective</h3><p>This work builds on efforts using X-ray computed tomography (XCT) characterize voids and their evolution under loading.</p><h3>Methods</h3><p>It employs <i>in-situ</i> XCT tensile testing on 316L Stainless Steel samples that were constructed by laser powder bed fusion that contain tailored, pre-existing voids with a spatial scale relevant to the growth and evolution stages of microvoid coalescence. Pre-existing voids extended the observation window for monitoring void growth and interaction under loading. They also enhanced fiducial correlation of voids during deformation.</p><h3>Results</h3><p>Void populations were found to increase under loading as their deformed dimensions rendered them detectable by the XCT algorithm. Neighboring voids underwent interconnection events by a cleavage process when stress concentrations between them exceeded the macroscopic yield stress. Pores that did not undergo interconnection events were found to revert to their initial size and population after unloading. Finally, the porosity structure before failure was correlated to features on the fracture surface with high fidelity.</p><h3>Conclusions</h3><p>This unique combination of <i>in-situ</i> XCT tensile testing on samples with tailored void structure enabled new visualization and quantification of void evolution under load as well as strong correlation to the observed stress–strain behavior and post-mortem fracture characteristics.</p></div>","PeriodicalId":552,"journal":{"name":"Experimental Mechanics","volume":"65 4","pages":"553 - 572"},"PeriodicalIF":2.0,"publicationDate":"2025-04-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11340-025-01180-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919139","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"On the Cover: Fatigue Damage Evolution in SS316L Produced by Powder Bed Fusion in Different Orientations with Reused Powder Feedstock","authors":"","doi":"10.1007/s11340-025-01179-w","DOIUrl":"10.1007/s11340-025-01179-w","url":null,"abstract":"","PeriodicalId":552,"journal":{"name":"Experimental Mechanics","volume":"65 4","pages":"421 - 421"},"PeriodicalIF":2.0,"publicationDate":"2025-04-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919028","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Influence of the Specimen Thickness on the Interlayer Shear Strengths of Additively Manufactured Polymers","authors":"B. Liu, X. Zheng, L.R. Xu","doi":"10.1007/s11340-025-01170-5","DOIUrl":"10.1007/s11340-025-01170-5","url":null,"abstract":"<div><h3>Background</h3><p>The shear strength of an engineering material is a critical mechanical parameter, however, its measurement often encounters challenges especially for new materials. Moreover, little research was conducted on the size effect of the shear strengths.</p><h3>Objective</h3><p>This study is to determine the specimen thickness effect on the interlayer shear strengths of two types of additively manufactured polymers.</p><h3>Methods</h3><p>A combined experimental and numerical investigation of the interlayer shear strength measurement was conducted, and its application targeted polylactic acid and polyamide using fused filament fabrication and selective laser sintering, respectively. A necking-shaped shear specimen was proposed to measure the interlayer shear strengths with the aid of both 3D finite element analysis and 3D digital image correlation.</p><h3>Results</h3><p>All specimens showed a consistent pure shear fracture pattern, and the shear strengths increased as the specimen thickness increased.</p><h3>Conclusions</h3><p>Future interlayer shear strength measurements should specify a fixed specimen thickness for fair comparisons.</p></div>","PeriodicalId":552,"journal":{"name":"Experimental Mechanics","volume":"65 4","pages":"597 - 602"},"PeriodicalIF":2.0,"publicationDate":"2025-03-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143919062","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Assessing the Potential of Heterogeneous Mechanical Tests for Sheet Metals Through Experimentally Measured Full-Fields","authors":"M. Gonçalves, S. Thuillier, A. Andrade-Campos","doi":"10.1007/s11340-025-01168-z","DOIUrl":"10.1007/s11340-025-01168-z","url":null,"abstract":"<div><h3>Background</h3><p>Numerical simulation is becoming essential in the mechanical design of sheet metal components, requiring advanced material models, composed of many unknown parameters, to accurately describe complex material behavior. Traditionally, these parameters are identified through multiple quasi-homogeneous tests, each providing specific mechanical data on a particular strain state. The emergence of heterogeneous mechanical tests has revolutionized this process by enabling the capture of a wide range of strain states in a single experiment.</p><h3>Objective</h3><p>This study focuses on the experimental analysis of three heterogeneous mechanical tests, previously studied numerically. The main objective is to confirm the quality and relevance of the mechanical deformation observed when using real data and evaluate the sensitivity of these tests to different high-strength steels.</p><h3>Methods</h3><p>Uniaxial loading tests were conducted on three different specimen designs, using Stereo Digital Image Correlation to capture the mechanical fields on the surface. Multi-DIC systems were used to measure the out-of-plane behavior observed for a specimen design to increase the strain richness provided by the test. The repeatability of these tests is checked due to their complex designs.</p><h3>Results</h3><p>The results show that the potential of heterogeneous mechanical tests remains unchanged when tested in real-world experimental settings.</p><h3>Conclusions</h3><p>When combined with full-field measurement techniques, these can provide a wide range of mechanical behavior data from a single test, reducing the number of tests needed for advanced material characterization.</p></div>","PeriodicalId":552,"journal":{"name":"Experimental Mechanics","volume":"65 5","pages":"757 - 774"},"PeriodicalIF":2.0,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11340-025-01168-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144074146","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
S. Langlois, F. Benboudjema, M. Maaroufi, F. Hafid, B. Smaniotto, F. Hild, A. Fau
{"title":"Quantification of Reinforcement Debonding in Damaged Mortar via Digital Volume Correlation","authors":"S. Langlois, F. Benboudjema, M. Maaroufi, F. Hafid, B. Smaniotto, F. Hild, A. Fau","doi":"10.1007/s11340-025-01166-1","DOIUrl":"10.1007/s11340-025-01166-1","url":null,"abstract":"<div><h3>Background</h3><p>Debonding between a cementitious material and a reinforcement is a mechanical phenomenon of great interest. It cannot be quantified directly through standard tests since it occurs within the material bulk.</p><h3>Objective</h3><p>The goal is to develop an experimental method for quantifying debonding during <i>in-situ</i> pull-out tests that also induce damage in the mortar matrix.</p><h3>Method</h3><p>A 1/50 scale foundation model is subjected to a pull-out test in an X-ray tomograph. A finite-element-based Digital Volume Correlation analysis with mechanical regularization is conducted based on a three-dimensional mesh constructed to reproduce the geometry of the foundation and reinforcement.</p><h3>Results</h3><p>Heterogeneous regularization with a single-node mesh has little effect on the correlation residuals. Using split nodes to describe the interface drastically reduces the correlation residuals in the reinforcement. If cracking occurs in addition to debonding, introducing a heterogeneous regularization based on damaged elements improves the quantification of debonding.</p><h3>Conclusion</h3><p>By splitting the nodes at the interface and localizing regularization in damaged elements, the reinforcement and mortar kinematics is better captured and thus debonding as well.</p></div>","PeriodicalId":552,"journal":{"name":"Experimental Mechanics","volume":"65 5","pages":"799 - 817"},"PeriodicalIF":2.0,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s11340-025-01166-1.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144074145","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Development of a P‒T-Model-Based In-Situ Bending Measurement Method for Nanowires: Addressing Mechanical Challenges in High-Precision Experiments","authors":"Y. Ai, J. Shang, Y. Gong, S. Liu","doi":"10.1007/s11340-025-01169-y","DOIUrl":"10.1007/s11340-025-01169-y","url":null,"abstract":"<div><h3>Background</h3><p>The <i>in situ</i> mechanical measurement of nanomaterials using microelectromechanical system accessories in electron microscopy has attracted considerable interest because of its ability to combine microstructure responses and stress conditions.</p><h3>Objective</h3><p>In this study, an <i>in situ</i> large-deflection longitudinal‒transverse bending measurement technique was developed in a double-cantilever beam system using transmission electron microscopy (TEM).</p><h3>Methods</h3><p>Nonlinear large-strain bending tests of raw and high-temperature-oxidized 3C-silicon carbide (3C-SiC) nanowires (NWs) were performed using TEM. After an explicit polynomial–trigonometric combined-function (P‒T model) was introduced to fit the NW contour in each image frame, a mechanical algorithm based on the fitting curve was proposed to calculate the stress and strain in batches.</p><h3>Results</h3><p>Contour modeling analysis using the P‒T model revealed brittle fracture in a 104-nm-diameter SiC NW with a fracture strain of 3.46% and a modulus of 590.8 GPa. Plastic deformation occurred during the bending of a 430-nm-diameter oxidized core–shell SiC-SiO<sub>2</sub> NW, with a fracture strain exceeding 7.07% and a modulus of 42.6 GPa.</p><h3>Conclusion</h3><p>Compared with results from other widely used approximation fitting models, the measurement results based on the P‒T method were more accurate and stable. The modulus reduction and brittle‒ductile transition induced by the amorphous oxide layer on the SiC core were demonstrated using the P‒T method.</p></div>","PeriodicalId":552,"journal":{"name":"Experimental Mechanics","volume":"65 5","pages":"775 - 798"},"PeriodicalIF":2.0,"publicationDate":"2025-03-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144074147","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"A Novel Approach to Dynamic Equi-Biaxial Testing of Thin Flexible Materials Using the Ring-on-Ring Test Method","authors":"K. Goyal, C. Singh, G. Subhash","doi":"10.1007/s11340-025-01167-0","DOIUrl":"10.1007/s11340-025-01167-0","url":null,"abstract":"<div><h3>Background</h3><p>The current ASTM formulation for determining dynamic ring-on-ring test method is applicable for thick plates and is not suitable for thin plates that can undergo large flexural deformation where membrane stresses dominate.</p><h3>Objective</h3><p>The objective is to design and develop a new dynamic ring-on-ring test method with the ability to accurately measure load and visually access the tensile surface of a specimen for tracking failure. It is also aimed to develop a scientifically robust test procedure and analysis method to validate this new design for obtaining accurate biaxial flexural strength of thin flexible plates.</p><h3>Methods</h3><p>A unique load-cell assembly that houses a doughnut-shaped loadcell and capable of preloading the loadcell to a desired force level while simultaneously providing an unobstructed line-of-sight for a high-speed camera to capture the evolving damage modes in the specimen is developed. This loadcell assembly is used in a Hopkinson bar setup to test thin glass specimens and determine their dynamic biaxial flexural fracture strength. A new calibration procedure is proposed that accounts for the delay in the force sensed by the loadcell and provides a more accurate measure of the applied dynamic load on the specimen surface. An analysis method that accounts for membrane stresses under axisymmetric loading is developed to determine the biaxial failure strength of thin glass specimens that undergo large flexural deformation.</p><h3>Results</h3><p>A loadcell calibration method, an experimental procedure to dynamically test thin flexible specimens, and an analysis method that accounts for membrane stresses were developed. The Experimental results for three types of thin transparent materials reveal that the dynamic flexural failure strength is 40% more than their corresponding quasistatic strength. Radial cracks evolve from a preexisting defect during the biaxial loading and the damage growth rate was determined to be 1570 m/s.</p><h3>Conclusions</h3><p>The results reveal that the formulation suggested by the ASTM standard overpredicts the failure strength of thin glass specimen by several times the strength determined by the developed analytical method that accounts for the membrane stress. The analysis procedure provides a repeatable measurement of dynamic biaxial failure strength of flexible thin plates.</p></div>","PeriodicalId":552,"journal":{"name":"Experimental Mechanics","volume":"65 5","pages":"743 - 756"},"PeriodicalIF":2.0,"publicationDate":"2025-03-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144073845","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}