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This study aims to evaluate the low energy impact characteristics of 3D printed carbon fiber thermoplastic and thermoset polymer composite using the Izod impact test. The effects of infill density are examined on the Izod impact properties of 3D printed thermoset polymer and thermoplastic composite specimens. Furthermore, a thorough investigation is conducted into the effect of heat treatment using a hot-air oven on both types of 3D printed composite specimens. To characterize the impact characteristics of each specimen, the fracture surfaces caused by impact load are inspected, and the fracture mechanism is studied using scanning electron micrographs.

Izod Impact specimens of thermoset (epoxy resin) and thermoplastic carbon fiber of different infill density (70, 75, 80, 85, 90 and 100%) are fabricated using the different fiber impregnation 3D printing process. To carry out the heat treatment process, printing of composites is done for each infill design from both thermoset and thermoplastic composites and the impact characteristics of specimens are evaluated on a pendulum test-rig using the ASTM D-256 standard. Using a scanning electron microscope, each fracture zone underwent four separate scanning processes, ranging in size from 2 µm to 100 µm.

The impact resistance of the 3D printed thermoset and thermoplastic composite material is significantly influenced by the type of fiber placement and infill density in the matrix substrate. Because of the weak interfacial strength between the layers of fiber and polyamide 6, the specimen printed with continuous fiber implanted at the part exhibited reduced impact resistance. At 75% infill density, the impact specimen printed with coextruded fiber showed the highest impact resistance with a 367.02% greater magnitude than the continuous fiber specimen with the same infill density.

This work presents a novel approach to analyze the low energy impact characteristics and three-dimensional printing of carbon fiber reinforced thermoplastic and carbon fiber reinforced thermoset and thermoplastic composite material.

This paper aims to investigate the bond strength of metakaolin-based geopolymer mortar with cement mortar.

The mortar-mortar bond strength is assessed by slant shear and split tensile tests; pure shear strength is evaluated by Mohr’s criterion for result validation. Metakaolin-based geopolymer mortar is cast over the cured cement mortar specimen with two levels of surface roughness: smooth or grooved interface. The influence of the alkaline solution to metakaolin ratio on geopolymer bond strength is studied. Compressive strength, ultrasonic pulse velocity, permeability and flow table tests are also performed.

The paper’s findings are highlighted as follows: (1) strong mortar-mortar bond properties achieved for geopolymer mortar in all tests and conditions and validated by Mohr’s criterion and pure shear, (2) a lower alkaline solution to metakaolin ratio achieves higher bond strength to Portland cement mortar and (3) geopolymer mortar has higher compressive strength and ultrasonic pulse velocity than cement mortar at all curing ages; additionally, it is more flowable and less permeable.

The full replacement of Portland cement with metakaolin, a more sustainable cementitious material, will contribute to the decarbonization of the construction industry.

Limited research has been carried out on the bond strength of metakaolin-based geopolymer mortar to Portland cement mortar. Also, computing the pure shear using Mohr’s circle criterion of metakaolin-based geopolymer to validate the results can be considered original.

The purpose of this paper is to evaluate the effect of titanium oxide (TiO₂) and yttrium oxide (Y₂O₃) nanoparticles-reinforced pure aluminium (Al) on the mechanical properties of hybrid aluminium matrix nanocomposites (HAMNCs).

The HAMNCs were fabricated via a vacuum die-assisted stir casting route by a two-step feeding method. The varying weight percentages of TiO₂ and Y₂O₃ nanoparticles were added as 2.5, 5, 7.5 and 10 Wt.%.

Scanning electron microscope images showed the homogenous dispersion of nanoparticles in Al matrix. The tensile strength by 28.97%, yield strength by 50.60%, compression strength by 104.6% and micro-hardness by 50.90% were improved in HAMNC1 when compared to the base matrix. The highest values impact strength of 36.3 J was observed for HAMNC1. The elongation % was decreased by increasing the weight percentage of the nanoparticles. HAMNC1 improved the wear resistance by 23.68%, while increasing the coefficient of friction by 14.18%. Field emission scanning electron microscope analysis of the fractured surfaces of tensile samples revealed microcracks and the debonding of nanoparticles.

The combined effect of TiO₂ and Y₂O₃ nanoparticles with pure Al on mechanical properties has been studied. The composites were fabricated with two-step feeding vacuum-assisted stir casting.

This study examines how different stacking sequences of bamboo and flax fibers, treated with 5% aqueous sodium hydroxide (NaOH) and filled with 6wt% titanium oxide (TiO₂), affect the physical, mechanical and dry sliding wear resistance properties of a hybrid composite.

Composites with different fiber stacking arrangements were developed and tested per American Society for Testing and Materials (ASTM) standards to evaluate physical, mechanical and wear resistance properties, focusing on the impact of flax fiber mats at intermediate and outer layers.

The hybrid composite significantly outperformed composites reinforced solely with bamboo fibers, showing a 65.95% increase in tensile strength, a 53.29% boost in flexural strength and a 91.01% improvement in impact strength. The configuration with multiple layers of flax fiber mat at intermediate and outer levels also demonstrated superior wear resistance.

This study highlights the critical role of stacking order in optimizing the mechanical properties and wear resistance of hybrid composites. The findings provide valuable insights for the design and application of advanced composite materials, particularly in industries requiring high performance and durability.

This study used an indentation-based mechanical testing framework for the mechanical characterization of laser powder bed fusion (LPBF) processed Inconel 718 on a wrought Inconel 718 substrate. The purpose of the paper is to investigate the effectiveness of the indentation-based approach for localized mechanical evaluation.

The LPBF-processed wrought substrate was sectioned into three sections for microstructural and mechanical characterization. A 3D heat source model was used for the thermal analysis of the interface region. The developed interface region is probed using the Knoop hardness indenter in different orientations to determine the textural anisotropy and mechanical behavior of the region.

LPBF process develops a melted interface zone (MIZ) at the deposition-substrate interface. The MIZ exhibited a coarse grain structure region along with a larger primary dendritic arm spacing (PDAS), signifying a slower cooling rate. FE modeling of the LPBF process reveals heat accumulation in the substrate along with intrinsic heat treatment (IHT) induced due to layer-wise processing. The obtained yield locus shows strong anisotropy in the deposition region, whereas reduced anisotropy with a nearly uniform ellipse locus for the MIZ regions. This reduced anisotropy is attributable to IHT and heat accumulation in the substrate.

An alternative localized mechanical characterization tool has been investigated in this work. The approach proved sensitive to thermal variations during LPBF processing in an isolated region which extends its suitability to variable geometry parts. Moreover, the approach could serve as a screening tool for parts made from dissimilar metals.

This study aims to improve the mechanical properties of an object produced by fused deposition modelling with high-grade polymer.

The study uses an ensembled surrogate-assisted evolutionary algorithm (SAEA) to optimize the process parameters for example, layer height, print speed, print direction and nozzle temperature for enhancing the mechanical properties of temperature-sensitive high-grade polymer poly-ether-ether-ketone (PEEK) in fused deposition modelling (FDM) 3D printing while considering print time as one of the important parameter. These models are integrated with an evolutionary algorithm to efficiently explore parameter space. The optimized parameters from the SAEA approach are compared with those obtained using the Gray Relational Analysis (GRA) Taguchi method serving as a benchmark. Later, the study also highlights the significant role of print direction in optimizing the mechanical properties of FDM 3D printed PEEK.

With the use of ensemble learning-based SAEA, one can successfully maximize the ultimate stress and percentage elongation with minimum print time. SAEA-based solution has 28.86% higher ultimate stress, 66.95% lower percentage of elongation and 7.14% lower print time in comparison to the benchmark result (GRA Taguchi method). Also, the results from the experimental investigation indicate that the print direction has a greater role in deciding the optimum value of mechanical properties for FDM 3D printed high-grade thermoplastic PEEK polymer.

This study is valid for the parameter ranges, which are defined to conduct the experimentation.

This study has been conducted on the basis of taking only a few important process parameters as per the literatures and available scope of the study; however, there are many other parameters, e.g. wall thickness, road width, print orientation, fill pattern, roller speed, retraction, etc. which can be included to make a more comprehensive investigation and accuracy of the results for practical implementation.

This study deploys a novel meta-model-based optimization approach for enhancing the mechanical properties of high-grade thermoplastic polymers, which is rarely available in the published literature in the research domain.

The current study aims to develop a 3D-printed continuous metal fiber-reinforced recycled thermoplastic composite using an in-nozzle impregnation technique.

Recycled acrylonitrile butadiene styrene (RABS) plastic was blended with virgin ABS (VABS) plastic in a ratio of 60:40 weight proportion to develop a 3D printing filament that was used as a matrix material, while post-used continuous brass wire (CBW) was used as a reinforcement. 3D printing was done by using a self-customized print head to fabricate the flexural, compression and interlaminar shear stress (ILSS) test samples to evaluate the bending, compressive and ILSS properties of the build samples and compared with VABS and RABS-B samples. Moreover, the physical properties of the samples were also analyzed.

Upon three-point bend, compression and ILSS testing, it was found that RABS-B/CBW composite 3D printed with 0.7 mm layer width exhibited a notable improvement in maximum flexural load (L_max), flexural stress at maximum load (sf_max), flex modulus (E_f) and work of fracture (WOF), compression modulus (E_c) and ILSS properties by 30.5%, 49.6%, 88.4% 13.8, 21.6% and 30.3% respectively.

Limited research has been conducted on the in-nozzle impregnation technique for 3D printing metal fiber-reinforced recycled thermoplastic composites. Adopting this method holds the potential to create durable and high-strength sustainable composites suitable for engineering applications, thereby diminishing dependence on virgin materials.

The purpose of this study is the formation and growth of nanoscale intermetallic compounds (IMCs) when laser is used as a heat source to form solder joints.

This study investigates the Sn/Cu and Sn-0.1AlN/Cu structure using laser soldering under different laser power: (200, 225 and 250 W) and heating time: (2, 3 and 4 s).

The results show clearly that the formation of nano-Cu₆Sn₅ films is feasible in the laser heating (200 W and 2 s) with Sn/Cu and Sn-0.1AlN/Cu system. The nano-Cu₆Sn₅ films with thickness of 500 nm and grains with 700 nm are generally parallel to the Cu surface with Sn-0.1AlN. Both IMC films thickness of Sn/Cu and Sn-0.1AlN/Cu solder joints gradually increased from 524.2 to 2025.8 nm as the laser heating time and the laser power extended. Nevertheless, doping AlN nanoparticles can slow down the growth rate of Cu₆Sn₅ films in Sn solder joints due to its adsorption.

The formation of nano-Cu₆Sn₅ films using laser heating can provide a new method for nanofilm development to realize the metallurgical interconnection in electronic packaging.

Herein, the authors report the effects of printing parameters, joining method, and annealing conditions on the structural performance of fusion-joined short-beam sections produced by additive manufacturing.

The authors first identified appropriate printing parameters for joining segmented short beams and then used those parameters to print and fusion-join segments with different configurations of stiffeners to form a longer section of a wing or small wind turbine blade structure.

It was found that the beams with three lateral and three base stiffening ribs give the highest flexural strength among the three beams investigated. Results on joined beams annealed at different conditions showed that annealing at 70 °C for 0.5 h yields higher performance than annealing at the same temperature for longer times. It is also found that in the case of the hot-plate-welded three-dimensional (3D)-printed structures, no annealing is needed for reaching a high strength-to-weight ratio, but annealing is helpful for maximizing the modulus-to-weight ratio. Both thermal buckling and edge wrapping were observed under annealing at 70°C for 0.5 h for 3D-printed beams comprising two lateral and four base stiffening plates.

Fusion-joining of additively manufactured segments is needed owing to the constraint in building volume of a typical commercial 3D-printer. However, study of the effect of process parameters is needed to quantify their effect on mechanical performance. This investigation has therefore identified key printing parameters and annealing conditions for fusion-joining short segments to form larger structures, from multiple 3D-printed sections, such as wind blade structures.

One of the often-employed building constituents in the construction sector is concrete, which involves hydration of cement, leading to the generation of carbon footprints during its production. Also, massive amount of natural aggregate is illegally mined, which poses serious environmental issues along with ecological misbalance. Researchers are in continuous search of appropriate substitutes to mitigate those challenges and develop innovative concrete mix. Consequently, depletion of natural resources, the disturbances to the environmental and ecological imbalance will reduce. The purpose of this study is to develop a Portland Slag Cement based novel sustainable concrete incorporating Alccofine and Recycled Refractory Brick as fractional replacement of cement and fine aggregate, respectively and evaluate its destructive, non-destructive and microstructural properties.

M25 grade of concrete adopting 0.45 water-binder proportion, with diverse percentage of Alccofine as fractional substitution of cement and 20% of recycled refractory brick (RRB) as fine aggregate, has been cast and evaluated for diverse mechanical strength following a curing of 7, 14 and 28 days. Scanning electron microscopic analysis has been carried out to study the microstructural changes in the specimens.

Supplementary use of Alccofine enhanced normal compressive strength of sustainable concrete mix blended with Portland Slag Cement by a large amount at all levels of 7, 14 and 28 days of curing. Test results indicated development of a favourable high-strength sustainable concrete mix by substituting cement with Alccofine.

This manuscript has demonstrated the possibility of developing sustainable concrete blends by incorporating Alccofine 1203 and RRB as partial replacement of Portland Slag Cement and natural fine aggregate, respectively. The strength and potential of concrete incorporating RRB for wider and special application in adverse environmental conditions having higher thermal gradient, as RRB is a valuable waste from high temperature kiln and furnaces. Alccofine 1203 has been included in the concrete mix as an alternative to Portland Slag Cement to improve the mechanical strength properties and durability of concrete intended for adverse environmental application.