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It is well known that stress singularity may exist at the edges of a bonded bi‐material interface due to the discontinuity of material properties. This stress singularity causes difficulty in accurately determining the bi‐material interface bonding strength. This paper aims to present a new design of specimen geometry to eliminate the stress singularity and present an experimental procedure to more accurately determine the bonding strength of the bi‐material interface.

The design is based on an asymptotic analysis of the stress field near the free edge of bi‐material interface. The critical bonding angle, which delineates the singular and non‐singular stress field near the free edge, is determined.

With the new designed specimen and a special iterative calculation algorithm, the interface bonding strength envelope of an epoxy‐aluminum interface was experimentally determined.

This new design of specimen, experimental procedure and iterative algorithm may be applied to obtain more reasonable and accurate bonding strength data for a wide range of bi‐material interfaces.

Currently on additive manufacturing, extensive research is directed toward mitigating the main challenges associated with multi-material in fused filament fabrication which has a weak bonding strength between dissimilar materials. Low interfacial bonding strength leads to defects, anisotropy and temperature gradient in materials which negatively impact the mechanical performance of the multi-material prints. The purpose of this study was to assess the performance of different interface geometry designs in terms of the mechanical properties of the specimens.

Tensile test specimens were printed using: mono-material without a boundary interface, mono-material with the interface geometries (Face-to-face; U-shape; T-shape; Dovetail; Encapsulation; Mechanical interlocking; and Overlap) and multi-material with the interface geometries. The materials chosen with high and low compatibility were Tough polylactic acid (PLA) and TPU.

The main results of this study indicate that the interface geometries with the mechanical constriction between materials provide better structural integrity to the specimens. Moreover, in the case of the mono-material parts, the most effective interface design was the mechanical interlocking for both Tough PLA and TPU. On the other hand, in the case of multi-material specimens, the encapsulation showed the highest ultimate tensile strength, whereas the overlap and T-shape presented more robust bonding.

This study examines the mechanical performance, particularly tensile strength, strain at break, Young’s modulus and yield strength of different interface designs which were not studied in the previous studies.

An issue when printing multi-material objects is understanding how different materials will perform together, especially because interfaces between them are always created. This paper aims to address this interface from a mechanical perspective and evaluates how it should be designed for a better mechanical performance.

Different interface mechanisms were considered, namely, microscopic interfaces that are based on chemical bonding and were represented with a U-shape interface; a macroscopic interface characterized by a mechanical interlocking mechanism, represented by a T-shape interface; and a mesoscopic interface that sits between other interface systems and that was represented by a dovetail shape geometry. All these different interfaces were tested in two different material sets, namely, poly (lactic acid)–poly (lactic acid) and poly (lactic acid)–thermoplastic polyurethane material pairs. These two sets represent high- and low-compatibility materials sets, respectively.

The results showed, despite the materials’ compatibility level, multi-material objects will have a better mechanical performance through a macroscopic interface, as it is based on a mechanical interlocking system, of which performance cannot be achieved by a simple face-to-face interface even when considering the same material.

The paper investigates the importance of interface design in multi-material 3D prints by fused filament fabrication. Especially, for parts intended to be subjected to mechanical efforts, simple face-to-face interfaces are not sufficient and more robust and macroscopic-based interface geometries (based on mechanical interlocking systems) are advised. Moreover, such interfaces do not raise esthetic problems because of their working principle; the 3D printing technology can hide the interface geometries, if required.

The small dimensions of future device designs also imply a stronger effect of material boundary resistance. For nanoscale devices and structures, especially, interface phenomena often dominate their overall thermal behavior. The purpose of this paper is to propose molecular dynamics (MD) simulations to investigate the mechanical and thermal properties at Cu‐Al interface.

The two‐temperature model (TTM)‐MD model is used to describe the electron‐phonon scattering at interface of different metals. Before the simulation of heat transfer process, a non‐ideal Cu‐Al interface is constructed by simulating diffusion bonding.

According to the simulation results, in unsteady state, the temperature distribution and the displacements of atoms near the interface tend to generate stress and voids. It reveals the damage mechanics at the interface in heat transfer.

The atomic model proposed in this paper is computationally efficient for interfacial heat transfer problems, and could be used for investigation of other interfacial behaviors of dissimilar materials.

This paper proposes an interpolating approach of the element‐free Galerkin method (EFGM) coupled with a modified truncation scheme for solving Poisson's boundary value problems in domains involving material non‐homogeneities. The suitability and efficiency of the proposed implementation are evaluated for a given set of test cases of electrostatic field in domains involving different material interfaces.

The authors combined an interpolating approximation with a modified domain truncation scheme, which avoids additional techniques for enforcing the Dirichlet boundary conditions and for dealing with material interfaces usually employed in meshfree formulations.

The local electric potential and field distributions were correctly described as well as the global quantities like the total potency and resistance. Since, the treatment of the material interfaces becomes practically the same for both the finite element method (FEM) and the proposed EFGM, FEM‐oriented programs can, thus, be easily extended to provide EFGM approximations.

The robustness of the proposed formulation became evident from the error analyses of the local and global variables, including in the case of high‐material discontinuity.

The proposed approach has shown to be as robust as linear FEM. Thus, it becomes an attractive alternative, also because it avoids the use of additional techniques to deal with boundary/interface conditions commonly employed in meshfree formulations.

This paper reintroduces the domain truncation in the EFGM context, but by using a set of interpolating shape functions the authors avoided the use of Lagrange multipliers as well as of a penalty strategy. The resulting formulation provided accurate results including in the case of high‐material discontinuity.

The purpose of this paper is as follows: to significantly reduce the computation time (by a factor of 1,000 and more) compared to known numerical techniques for real-world problems with complex interfaces; and to simplify the solution by using trivial unfitted Cartesian meshes (no need in complicated mesh generators for complex geometry).

This study extends the recently developed optimal local truncation error method (OLTEM) for the Poisson equation with constant coefficients to a much more general case of discontinuous coefficients that can be applied to domains with different material properties (e.g. different inclusions, multi-material structural components, etc.). This study develops OLTEM using compact 9-point and 25-point stencils that are similar to those for linear and quadratic finite elements. In contrast to finite elements and other known numerical techniques for interface problems with conformed and unfitted meshes, OLTEM with 9-point and 25-point stencils and unfitted Cartesian meshes provides the 3-rd and 11-th order of accuracy for irregular interfaces, respectively; i.e. a huge increase in accuracy by eight orders for the new 'quadratic' elements compared to known techniques at similar computational costs. There are no unknowns on interfaces between different materials; the structure of the global discrete system is the same for homogeneous and heterogeneous materials (the difference in the values of the stencil coefficients). The calculation of the unknown stencil coefficients is based on the minimization of the local truncation error of the stencil equations and yields the optimal order of accuracy of OLTEM at a given stencil width. The numerical results with irregular interfaces show that at the same number of degrees of freedom, OLTEM with the 9-points stencils is even more accurate than the 4-th order finite elements; OLTEM with the 25-points stencils is much more accurate than the 7-th order finite elements with much wider stencils and conformed meshes.

The significant increase in accuracy for OLTEM by one order for 'linear' elements and by 8 orders for 'quadratic' elements compared to that for known techniques. This will lead to a huge reduction in the computation time for the problems with complex irregular interfaces. The use of trivial unfitted Cartesian meshes significantly simplifies the solution and reduces the time for the data preparation (no need in complicated mesh generators for complex geometry).

It has been never seen in the literature such a huge increase in accuracy for the proposed technique compared to existing methods. Due to a high accuracy, the proposed technique will allow the direct solution of multiscale problems without the scale separation.

The simulation of the fluid–solid interaction (FSI) problem is important for both academic studies and engineering applications. However, the numerical approach for simulating the FSI problems is a great challenge owing to the large discrepancy of material properties and inconsistent description of grid motion between the fluid and solid domains. The difficulties will be further increased if there are multiple materials in the fluid region. In these complicated applications, interface reconstruction, multi-material advection and FSI must be all taken into account. This paper aims to present an effective integrated work of multi-material arbitrary Lagrangian Eulerian (MMALE) method, finite element (FE) method and the continuum analogy method to simulate the complex FSI problems involving multi-material flow. The coupled method is used to simulate the three-dimensional CONT test and the blast-plate interaction. The numerical results show good agreement with the benchmark and the experiment data, which indicates that the presented method is effective for solving the complicated FSI problems.

MMALE and FE methods are used to simulate fluid and solid regions, respectively. The interfacial nodes of fluid and solid are required to be coincident in the whole simulation so the interacted force can be easily and accurately calculated. To this end, the continuum analogy method is used in the rezoning phase.

The coupled method is used to simulate the three-dimensional CONT test and the blast-plate interaction. The numerical results show good agreement with the benchmark and the experiment data, which indicates that the presented method is effective for solving the complicated FSI problems.

To the best of the authors’ knowledge, this is the first time that the ALE method, moment of fluid interface reconstruction method, continuum analogy method and the FE method are combined to solve complicated practical problems.

Shape deposition manufacturing (SDM) is a layered manufacturing process which iteratively combines material addition and removal to create artifacts in a variety of materials. Castable thermoset resins have been used to build a variety of parts via polymer SDM. The strength of these parts is determined by the bulk material properties of the part materials and by their interlayer adhesion. Early polyurethane materials had high bulk strength but poor interlayer adhesion, resulting in weak multilayer parts. Interlayer strength improvements were achieved through additional processing steps or the use of different polyurethane and epoxy part materials. These improvements allowed the fabrication of aerodynamic flap mechanisms used in wind‐tunnel testing. These parts are examples of the intricate, functional mechanisms to which the polymer SDM process is ideally suited.

This paper proposes to extend the combination of Extended Finite Element Method (XFEM) and Level Set Method (LSM) from structural mechanics to electromagnetics. Based on this approach, the actual stage of the research work, dedicated to the investigation, development, implementation and validation of a shape optimization methodology, particularly tailored for 2D electric structures is described.

The proposed numerical approach is based on the efficiency of the XFEM and the flexibility of the LSM, to handle moving material interfaces without remeshing the whole studied domain at each optimization step.

This approach eliminates the conventional use of discrete finite elements and provides efficient, stable, accurate and faster computation schemes in comparison with other methods.

This research is limited to shape optimization of two‐dimensional electric structures, however, the work can be extended to 3D ones too.

The implementation of the proposed numerical approach for the shape optimization of a planar resistor is hereby described.

The main value of the proposed approach is a powerful and robust numerical shape optimization algorithm that demonstrates outstanding suppleness of handling topological changes, fidelity of boundary representation and a high degree of automation in comparison with other methods.

The purpose of this paper is to compute the stress intensity factors (SIFs) of single edge interface crack for arbitrary material combinations and various relative crack lengths, and compare with those for the bonded plates subjected to tensile loading conditions. It aims to discuss the results of the shallow edge interface crack on the basis of the singular stress near the free‐edge corner without the crack.

In this study, the SIFs of interface crack in dissimilar bonded plates subjected to bending loading conditions are analyzed by the finite element method and a post‐processing technique. The use of post‐processing technique of extrapolation reduces the computational cost and improves the accuracy of the obtained result.

The empirical expressions are proposed for evaluating the SIFs of arbitrary material combinations.

Empirical functions can be used to obtain the SIFs for arbitrary material combinations for the bending loading conditions easily. It is very convenient for engineering application.