Mesostructure optimization in multi-material additive manufacturing: a theoretical perspective

As multi-material additive manufacturing technologies mature, a new opportunity for materials science and engineering emerges between the scale of the microstructure and the scale of an engineering component. Here we explore the problem of “mesostructure optimization,” the computational identification of preferred point-to-point distributions of material structure and properties. We illustrate the opportunity with two simple example problems for 1D and 2D mesostructure optimization, respectively, namely (1) a functionally graded cylinder that is computationally optimized to redistribute the Hertzian contact stress fields and (2) a thin plate made of digital materials computationally designed to simultaneously maximize bending resistance and minimize total weight. The mechanical performance of materials in these two problems is significantly improved as compared to any monolithic-material counterpart, including a topology-optimized monolith in case (2). These results point to new opportunities for multi-objective performance enhancement in materials.     

On the Room-Temperature Mechanical Properties of an Ion-Irradiated TiZrNbHfTa Refractory High Entropy Alloy

JOM - Refractory high-entropy alloys (RHEAs) are potential candidate materials for use in next-generation nuclear reactors due to their excellent mechanical performance at high temperatures. Here,...     

Geometric Charts with Estimated Control Limits

The geometric control chart has been shown to be more effective than p and np‐charts for monitoring the proportion of nonconforming items, especially for high‐quality Bernoulli processes. When implementing a geometric control chart, the in‐control proportion nonconforming is typically unknown and must be estimated. In this article, we used the standard deviation of the average run length (SDARL) and the standard deviation of the average number of inspected items to signal, SDARL*, to show that much larger phase I sample sizes are needed in practice than implied by previous research. The SDARL (or SDARL*) was used because practitioners would estimate the control limits based on different phase I samples. Thus, there would be practitioner‐to‐practitioner variability in the in‐control ARL (or ARL*). In addition, we recommend a Bayes estimator for the in‐control proportion nonconforming to take advantage of practitioners' knowledge and to avoid estimation problems when no nonconforming items are observed in the phase I sample. If the in‐control proportion nonconforming is low, then the required phase I sample size may be prohibitively large. In this case, we recommend an approach to identify a more informative continuous variable to monitor. Copyright © 2012 John Wiley & Sons, Ltd.     

Failure probability prediction based on condition monitoring data of wind energy systems for spare parts supply

The feasibility of maintenance processes relies on the availability of spare parts. Spare part inventory planning is capital intensive. It is based on demand forecasting, which possesses a high potential in reducing inventories. Even if condition monitoring systems are installed in technical systems, condition monitoring information is barely used to predict the failure probability of units. Therefore, an enhanced forecast model, which integrates SCADA information, has been developed. This leads to more accurate spare part demand forecasts. The approach presented in the paper is based on data mining, the proportional hazards model (PHM) and a binomial distribution. It has been validated with maintenance data of wind energy systems.     

Textured PMN–PT and PMN–PZT

A promising way to improve the performance of piezoelectric ceramics is grain orientation by templated grain growth. In this work lead-based piezoelectric ceramics Pb(Mg_1/3Nb_2/3)_0.68Ti_0.32O₃ (PMN–32PT) and Pb(Mg_1/3Nb_2/3)_0.42(Ti_0.638Zr_0.362)_0.58O₃ (PMN–37PT–21PZ) ceramics were textured via templated grain growth process. For texturization (001)-oriented BaTiO₃ (BT) platelets (approximately 10 μm × 10 μm × 2 μm) were utilized as templates. The texturized ceramics were accomplished by aligning the templates by tape casting. The template growth into the matrix resulted in textured ceramics with Lotgering factors between 0.94 and 0.99 for both compositions. Consequences of the texture are enhanced dielectric and piezoelectric properties. Unipolar strain-field measurements of textured ceramics showed 0.25% strain s ₃₃ at 3 kV/mm. Large signal d ₃₃^* of up to 878 pm/V were determined directly from strain measurements. Compared with randomly oriented ceramics in texturized samples unipolar strain s ₃₃ and large signal d ₃₃^* was enhanced by a factor of up to 1.8.     

Oligocrystalline Shape Memory Alloys

Copper‐based shape memory alloys (SMAs) exhibit excellent shape memory properties in single crystalline form. However, when they are polycrystalline, their shape memory properties are severely compromised by brittle fracture arising from transformation strain incompatibility at grain boundaries and triple junctions. Oligocrystalline shape memory alloys (oSMAs) are microstructurally designed SMA structures in which the total surface area exceeds the total grain boundary area, and triple junctions can even be completely absent. Here it is shown how an oligocrystalline structure provides a means of achieving single crystal‐like SMA properties without being limited by constraints of single crystal processing. Additionally, the formation of oSMAs typically involves the reduction of the size scale of specimens, and sample size effects begin to emerge. Recent findings on a size effect on the martensitic transformation in oSMAs are compared and a new regime of heat transfer associated with the transformation heat evolution in these alloys is discussed. New results on unassisted two‐way shape memory and the effect of loading rate in oSMAs are also reported.     

Tailor‐Made Polymer Multilayers

The fabrication of multilayer assemblies from polymeric compounds is an important tool for precise control of film architecture on the nanoscale. In this report, a general, novel approach for the preparation of well‐defined polymeric multilayers is described. To achieve this, sulfonyl‐azide group containing polymers are first generated and deposited as thin films onto solid (organic) substrates. Upon thermal activation, the system crosslinks and binds to the substrate via C–H bond insertion. Through step‐and‐repeat procedures, multilayer assemblies are then generated where all the individual layers are linked to each other. As the assembly process does not require any specific molecular interactions, the described process represents a general strategy to generate tailor‐made multilayer surface coatings with wide range of film thickness and composition.     

Single crystal growth in PMN-PT and PMN-PZT

Single crystal growth of lead-based piezoelectric ceramics Pb(Mg_1/3Nb_2/3)_0.68Ti_0.32O₃ (PMN-32PT) and Pb(Mg_1/3Nb_2/3)_0.42(Ti_0.638Zr_0.362)_0.58O₃ (PMN-37PT-21PZ) ceramics via templated grain growth (TGG) was investigated. (001)- and (111)-oriented BaTiO₃ (BT) single crystals and (001)-oriented SrTiO₃ (ST) single crystals (of approximately 2.5 × 2.5 × 1 mm) were utilized as seeds for the growth experiments. The piezoelectric single crystals were produced in a process that involves at first hot pressing of single crystal in cold isostatically pressed ceramics followed by subsequent sintering of the samples. Growth of (001)-oriented single crystals with BT seeds was observed in both PMN-32PT and PMN-37PT-21PZ matrices. The measured growth lengths were up to 140 and 65 μm, respectively. The grown (001)-oriented single crystals grown were rectangular. The measured growth lengths of the pyramidal-shaped (111) BT single crystals were up to 1 mm, which is much larger than the growth lengths of the (001) single crystals. Experiments on (001) ST-seeded single crystals were not successful. No single crystal growth was observed due to the dissolution of the ST single crystals in the PMN-PZT matrix. The differences were explained by defect-chemical considerations.     

Poled Composites with Nd-Mn-Doped PZT Fibers Under Bipolar Electrical Load

Using the sol-gel process, Nd-Mn-doped PZT fibers were produced. The PZT was doped with 2 mol% neodymium and 1.1 mol% manganese. For characterization, the fibers were embedded in a polymer. The resulting 1-3 composites were poled with constant electric field. Strain and polarization were measured by applying a bipolar sinusoidal voltage of high amplitude. Instead of the expected shifted butterfly-shaped strain hysteresis, an asymmetric strain-field relation was observed. It is characterized by a rather linear region in direction of the poling field and an inflated region without strain switching for reversed polarity. Within the temperature range from room temperature to 80degC, the strain switching seems to be suppressed. Measurements of the piezoelectric coefficient at superimposed electric field prove the blocking of strain switching. Cyclation experiments with sesquipolar load show a pronounced linearity of the strain loops that declines after more than 2 times 10⁴ cycles.