Multi-scale modeling of thermal expansion coefficients of C/C composites at high temperature

In-plane and out-of-plane coefficients of thermal expansion (CTEs) are important parameters for thermodynamic analysis of Carbon/Carbon (C/C) composite. In this study, CTEs of a high performance 3D orthogonal woven C/C composite at high temperature are studied by multi-scale mechanical modeling using the finite element method. Two representative volume element (RVE) models at different length scales are used to evaluate the CTEs of the C/C material. Micro-scale model predicts the CTEs at the fibre tow scale in the three orthogonal directions (x, y and z). The output results from the micro-scale model are then incorporated in the meso-scale model to obtain the in-plane and out-of-plane CTEs of the 3D C/C composite. The modeling results have good agreement with the experimental results reported in references. Based on the numerical approach, global CTEs of the 3D C/C composite are calculated from 300 to 2500 K, and their temperature dependences are discussed. The current applied multi-scale models provide an efficient approach to predict the CTEs of 3D textile materials, which will give some highlights for thermodynamic analysis and structures design of the C/C composite.     

Coefficients of nonlinear thermal expansion for fiber-reinforced composites

In the present study, a micromechanics model is proposed to predict the coefficients of nonlinear thermal expansion (CTEs) of fiber-reinforced composites. The influence of fiber aspect ratio on the CTEs is also investigated. It is noted that the parameters of fiber aspect ratio have a significant effect on both the longitudinal CTEs and transverse CTEs. The CTEs of composites are also very sensitive to the different fiber volume fractions. Moreover, the Young’s modulus and Poisson’s ratio of composites are taken into account in the present analysis. The theoretical derivations are applicable for the composites under mechanical or thermal environment conditions. The present model offers a direct prediction of CTEs and can account for the effects of fiber aspect ratio and volume fractions.     

2D Mechanical Metamaterials with Widely Tunable Unusual Modes of Thermal Expansion

Most natural materials expand uniformly in all directions upon heating. Artificial, engineered systems offer opportunities to tune thermal expansion properties in interesting ways. Previous reports exploit diverse design principles and fabrication techniques to achieve a negative or ultralow coefficient of thermal expansion, but very few demonstrate tunability over different behaviors. This work presents a collection of 2D material structures that exploit bimaterial serpentine lattices with micrometer feature sizes as the basis of a mechanical metamaterials system capable of supporting positive/negative, isotropic/anisotropic, and homogeneous/heterogeneous thermal expansion properties, with additional features in unusual shearing, bending, and gradient modes of thermal expansion. Control over the thermal expansion tensor achieved in this way provides a continuum‐mechanics platform for advanced strain‐field engineering, including examples of 2D metamaterials that transform into 3D surfaces upon heating. Integrated electrical and optical sources of thermal actuation provide capabilities for reversible shape reconfiguration with response times of less than 1 s, as the basis of dynamically responsive metamaterials.     

New Twists of 3D Chiral Metamaterials

Rationally designed artificial materials, called metamaterials, allow for tailoring effective material properties beyond (“meta”) the properties of their bulk ingredient materials. This statement is especially true for chiral metamaterials, as unlocking certain degrees of freedom necessarily requires broken centrosymmetry. While the field of chiral electromagnetic/optical metamaterials has become rather mature, the field of elastic/mechanical metamaterials is just emerging and wide open. This research news reviews recent theoretical and experimental progress concerning 3D chiral mechanical and optical metamaterials, with special emphasis on work performed at KIT.     

Effects of particle size on the thermal expansion behavior of SiCp/Al composites

The coefficients of thermal expansion (CTEs) of 20 vol% SiCp/Al composites fabricated by powder metallurgy process were measured and examined from room temperature to 450 °C. The SiC particles are in three nominal sizes 5, 20 and 56μm. The CTEs of the SiCp/Al composites were shown to be apparently dependent on the particle size. That the larger particle size, the higher CTEs of the composites, is thought to be due to the difference in original thermal residual stresses and matrix plasticity during thermal loading. At low temperature, the experimental CTEs show substantial deviation from the prediction of the elastic analysis derived by Kerner and rule of mixture (ROM), while the Kerner’s model agrees relatively well at high temperatures for the composite with the larger particle size.     

Apparent coefficient of thermal expansion and residual stresses in multilayer capacitors

The thermal expansion behavior and residual stresses in multilayer capacitor (MLC) systems are analyzed in the present study. An MLC consists of a laminate of multiple alternating electrode layers and dielectric layers sandwiched between two ceramic cover layers. An analytical model is developed to derive simple closed-form solutions for the apparent coefficients of thermal expansion (CTEs) of the laminate. Plasticity of electrodes is included in the analysis. The predicted apparent CTEs are compared with measurements of some laminated ceramic composites. The effects of plasticity on apparent CTEs and residual stresses in MLC systems are discussed.     

The cryogenic thermal expansion and mechanical properties of plasma modified ZrW2O8 reinforced epoxy

In this article, epoxy resin reinforced by negative thermal expansion material, ZrW₂O₈, was fabricated. The surface modification of ZrW₂O₈ particles was performed via plasma enhanced chemical vapor deposition (PECVD) process. As a result, a thin film was uniformly deposited on the surfaces of the ZrW₂O₈ particles, leading to an improvement of compatibility and dispersion of ZrW₂O₈ fillers inside epoxy matrix. Moreover, the coefficients of thermal expansion (CTEs) of the composite material containing 0-40 vol.% fillers were studied under cryogenic temperatures. The results showed a significant reduction in thermal expansion with increasing ZrW₂O₈ content. The cryogenic mechanical properties of ZrW₂O₈/epoxy composites were also investigated, showing the properties were improved by adding ZrW₂O₈ to certain content. In addition, the mechanical strength and modulus of the composite were observed significantly higher at cryogenic temperature than that at room temperature because of the thermal shrink effect and the frozen epoxy matrix.     

Origami Metamaterials for Tunable Thermal Expansion

Materials with engineered thermal expansion, capable of achieving targeted area/volume changes in response to variations in temperature, are important for a number of aerospace, optical, energy, and microelectronic applications. While most of the proposed structures with engineered coefficient of thermal expansion consist of bi‐material 2D or 3D lattices, here it is shown that origami metamaterials also provide a platform for the design of systems with a wide range of thermal expansion coefficients. Experiments and simulations are combined to demonstrate that by tuning the geometrical parameters of the origami structure and the arrangement of plates and creases, an extremely broad range of thermal expansion coefficients can be obtained. Differently from all previously reported systems, the proposed structure is tunable in situ and nonporous.     

Thermal expansion of isotropic Duralcan metal–matrix composites

The thermal expansion behaviour of Duralcan composites having a matrix of hypoeutectic Al–Si alloy containing SiC reinforcements ranging from 10–40 vol% was investigated. The coefficient of thermal expansion (CTE) of the MMCs was measured between 25 and 350 °C by a high-precision thermomechanical analyser, and compared to the predictions of three theoretical models. At low temperature, the experimental CTEs show substantial deviation from the predictions of the elastic analysis derived by Schapery, while the Kerner model agrees relatively well at high temperature. The overall measured CTE, in the range of 25–350 °C, as a function of the volume fraction of SiC is well predicted using Schapery's lower bound. We interpret these features as being an effect of reinforcement phase geometry and the modified microstructure derived from the Duralcan process and subsequent heat treatments. © 1998 Kluwer Academic Publishers     

Study on the Thermal Expansion and Thermal Cycling of AlNp／Al Composites

The AIN particle reinforced aluminum matrix composites with 50% volume fraction were fabricated by squeeze-casting technology.The thermal expansion behavior and its response to thermal cycling were studied between 20℃ and 400℃.Compared with four theoretical models,the measured CTEs of the composite lie within the elastic bounds derived by Schapery′s analysis .Schapery′s model and Kerner′s model agree well with the CTEs of the composites at lower temperature and elevated temperature,respectively.Strain hysteresis was observed between heating and cooling curves during cycling.This was attributed primarily to the anelastic behavior of the matrix induced by matrix residual stresses.     

平板式SOFC结构热应力的有限元分析

采用有限元数值计算方法, 对平板式固体氧化物燃料电池(SOFC)的结构建立了三维有限元分析模型, 模拟计算了平板式SOFC单电池在均匀温度场中由于各层部件之间的热膨胀系数差异而产生的热应力, 并对模拟结果进行了分析和讨论, 为优化平板式SOFC的材料选择和结构设计提供了依据. 计算结果表明: 在阳极(或阴极)与电解质界面处出现热应力的最大值; 界面热应力的大小及分布与电极材料的热膨胀系数和温度载荷密切相关.     

Tensile properties and thermal expansion behaviors of continuous molybdenum fiber reinforced aluminum matrix composites

The tensile properties and thermal expansion behaviors of continuous molybdenum fiber reinforced aluminum matrix composites (Mo_f/Al) have been studied. The Mo_f/Al composites containing different volume percents of Mo fibers were processed by diffusion bonding. The strengths of unidirectional Mo_f/Al composites were close to the rule-of-mixtures. The strengths of 0°/90° dual-directional composites increased with fiber content, while those of 45°/135° composites remained relatively low. The coefficients of thermal expansion (CTEs) of the composites decreased as the fiber content increased, close to the values of Mo fibers. With increasing temperature, the CTEs of unidirectional composites increased, while those of dual-directional composites decreased due to large accumulated thermal stresses. The CTEs of 45°/135° composites were lower than those of 0°/90° composites because of contraction effect. At temperatures above 250 °C, the CTEs of the dual-directional composites gradually increased due to matrix yielding and interfacial decohesion.     

Analyses of thermal expansion behavior of intergranular two-phase composites

Both analytical modeling and numerical simulations were performed to analyze residual thermal stresses and coefficients of thermal expansion (CTEs) of intergranular two-phase composites in a two-dimensional sense. A composite-circle model was adopted for analytical modeling. Model microstructures consisting of square-array, hexagon-array, and brick wall-array of grains with an intergranular phase as well as an actual microstructure of random-array grains with an intergranular phase were adopted for numerical simulations. The results showed that in predicting CTEs, the simple analytical model represents the two-dimensional composite well except that with brick wall-array grains, which induced significant anisotropic CTEs in the composite. The residual thermal stresses in composites were also discussed.     

3D-Printed Micro/Nano-Scaled Mechanical Metamaterials: Fundamentals,Technologies, Progress,Applications, and Challenges

Micro/nano-scaled mechanical metamaterials have attracted extensive attention in various fields attributed to their superior properties benefiting from their rationally designed micro/nano-structures. As one of the most advanced technologies in the 21st century, additive manufacturing (3D printing) opens an easier and faster path for fabricating micro/nano-scaled mechanical metamaterials with complex structures. Here, the size effect of metamaterials at micro/nano scales is introduced first. Then, the additive manufacturing technologies to fabricate mechanical metamaterials at micro/nano scales are introduced. The latest research progress on micro/nano-scaled mechanical metamaterials is also reviewed according to the type of materials. In addition, the structural and functional applications of micro/nano-scaled mechanical metamaterials are further summarized. Finally, the challenges, including advanced 3D printing technologies, novel material development, and innovative structural design, for micro/nano-scaled mechanical metamaterials are discussed, and future perspectives are provided. The review aims to provide insight into the research and development of 3D-printed micro/nano-scaled mechanical metamaterials.     

蜂窝结构力学超材料弹性及抗冲击性能的研究进展

具有手性蜂窝结构的力学超材料是近年来发展起来的高性能工程材料,它具有轻质、高比刚度、负泊松比、结构参数可调以及力学性能稳定等优点。其不仅可以实现面内变形,面外承载的双重力学作用,还具有出色的隔振、吸声降噪以及控制弹性波的传播等工程应用潜质,在智能结构、车辆船舶、航空航天等领域具有巨大的发展潜力。本文从其弹性和抗冲击两个力学性能方面进行综述。首先介绍并评述了近年来蜂窝结构力学超材料的面内杨氏模量、负泊松比特性以及面外剪切模量等弹性性能的理论分析研究进展。在抗冲击性能方面,从力学模型建立和有限元分析的角度出发,对手性蜂窝结构力学超材料在冲击载荷作用下的整体变形及其抗冲击性能的研究现状分别进行了评述。最后指出针对蜂窝结构力学超材料弹性及冲击性能的研究,可进一步建立内部韧带变形及力的传递力学模型以及深入探索冲击过程吸能机理等,以期为该类力学超材料内部韧带和节点环结构的优化设计提供参考。     

Recent progress in the design and fabrication of multifunctional structures based on metamaterials

Metamaterials, with unconventional properties realized through various ingenious designs of micro-architectures, have become a recent research hotspot in the fields of electromagnetics, acoustics, mechanics, and physics. Since the integration of mechanical features and specific functions is still a challenge, the application of metamaterials has so far been limited. The research in relevant areas has shown a clear trend of incorporating the multifunctional design into a single integrated structure. Here, we review the latest advances in the design and fabrication of multifunctional structures based on metamaterials, covering three main aspects, i.e., the direct design of mechanical metamaterials and their multifunctional structures, the intelligent multifunctional structures with shape-shifting capabilities, the metamaterials-based design to achieve both the load bearing capability and other specific functions. We emphasize the important roles that the mechanics-driven designs play, as well as the mechanisms and other key aspects behind the multifunctional structures. The structure-level innovations could not only improve multifunctional features, but also pave the way to function fusion structures that allow the incorporation of ‘conflicting’ functions into a single structure.     

Thermal expansion of a novel hybrid SiC foam–SiC particles–Al composites

A new type of hybrid SiC foam–SiC particles–Al composites (V_SiC = 53, 56.2 and 59.9%) to be used as an electronic packaging substrate material were fabricated by squeeze casting technique, and their thermal expansion behavior was evaluated. The coefficients of thermal expansion (CTEs) of the hybrid composites in the range of 20–100 °C were found to be between 6.6 and 7.7 ppm/°C. The measured CTEs are much lower than those of SiC particle-reinforced aluminum (SiC_p–Al) composites with the same content of SiC because of the characteristic interpenetrating structure of the hybrid composites. A material of such a low CTE is ideal for electronic packaging because of the low thermal mismatch (and therefore, low thermal stresses) between the electronic component and the substrate. To achieve similar CTEs in SiC_p–Al composites, the volume fraction of SiC would be much higher than that in the hybrid composites.     

Folding at the Microscale: Enabling Multifunctional 3D Origami‐Architected Metamaterials

Mechanical metamaterials inspired by the Japanese art of paper folding have gained considerable attention because of their potential to yield deployable and highly tunable assemblies. The inherent foldability of origami structures enlarges the material design space with remarkable properties such as auxeticity and high deformation recoverability and deployability, the latter being key in applications where spatial constraints are pivotal. This work integrates the results of the design, 3D direct laser writing fabrication, and in situ scanning electron microscopic mechanical characterization of microscale origami metamaterials, based on the multimodal assembly of Miura‐Ori tubes. The origami‐architected metamaterials, achieved by means of microfabrication, display remarkable mechanical properties: stiffness and Poisson’s ratio tunable anisotropy, large degree of shape recoverability, multistability, and even reversible auxeticity whereby the metamaterial switches Poisson’s ratio sign during deformation. The findings here reported underscore the scalable and multifunctional nature of origami designs, and pave the way toward harnessing the power of origami engineering at small scales.     

A review of additive manufacturing of metamaterials and developing trends

The concept of metamaterials originates from the proposal of left-hand materials with negative refractive index, followed by which, varieties of metamaterials with kinds of fantastic properties that cannot be found in natural materials, such as zero/negative Poisson’s ratio, electromagnetic/acoustic/thermal cloaking effect, etc., were come up with. According to their application fields, the metamaterials are roughly classified into four categories, electromagnetic metamaterials, acoustic metamaterials, thermal metamaterials, and mechanical metamaterials. By designing structures and arranging the distribution of materials with different physical parameters, the function of metamaterials can be realized in theory. Additive manufacturing (AM) technology provides a more direct and efficient way to achieve a sample of metamaterial and experiment verification due to the great advantages in fabricating complex structures. In this review, we introduce the typical metamaterials in different application situations and their design methods. In particular, we are focused on the fabrication of metamaterials and the application status of AM technology in them. Furthermore, we discuss the limits of present metamaterials in the aspect of design method and the disadvantages of existing AM technology, as well as the development tendency of metamaterials.