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The purpose of this paper is to study the statistics of thermal conductivity and resistivity tensors in two-phase random checkerboard microstructures at finite mesoscales.

Microstructures at finite scales are generated by randomly sampling an infinite checkerboard at 50 percent nominal fraction. Boundary conditions that stem from the Hill-Mandel homogenization condition are then applied as thermal loadings on these microstructures.

It is observed that the thermal response of the sampled microstructures is in general anisotropic at finite mesoscales. Based on 1,728 boundary value problems, the statistics of the tensor invariants (trace and determinant) are obtained as a function of material contrast, mesoscale and applied boundary conditions. The histograms as well as the moments (mean, variance, skewness and kurtosis) of the invariants are computed and discussed. A simple analytical form for the variance of the trace of mesoscale conductivity tensor is proposed as a function of individual phase conductivities and the mesoscale.

A rigorous methodology to determine the evolution of the invariants of thermal conductivity (and resistivity) tensors across a variety of length scales (microscale to macroscale) is presented. The objective is to enable setting up of constitutive equations applicable to heat conduction that are valid across all length scales.

The mesoscale structure (MS) has a significant impact on the mechanical performance of parts made by additive manufacturing (AM). This paper aims to explore the design and fabrication of force-flow guided reinforcement mesoscale structure (FFRMS) compared with the homogeneous mesoscale structure (HMS), which is inconsistent with the stress field for a given load condition. Some cases were presented to demonstrate the mechanical properties of FFRMS in terms of MS combined with quasi-isotropy and anisotropy.

The paper consists of four main sections: the first developed the concept of FFRMS design based on HMS, the second explored volume fraction control for the proportion of force-flow lines in terms of mechanical property requirement, and the third presented a sequence stacking theory and practical manufacturing process framework and the final sections provided some application case studies.

The main contributions of this study were the definition and development of the FFRMS concept, the application framework and the original case studies. As an example, a typical lug designed with the proposed FFRMS method was fabricated by three different AM processes. The test results showed that both the strength and stiffness of the specimens are improved greatly by using the FFRMS design method.

The superposition of HMS as the basement and force-flow as an indication of the stiffener, leading to a heterogeneous structure, which exhibits more efficient and diversified means compared with the traditional way of increasing the HMS density merely.

The purpose of this paper is to develop an efficient numerical method to study the complex crack initiation and propagation in linear elastic multiphase composites.

A phase field method is developed to study the complex fracture behavior in multiphase composites. A damage threshold is introduced for referring crack initiation in the proposed method. The damage threshold is assigned as a material property so that different composite components possess different thresholds. In this manner, smooth transition from crack initiation to propagation is revealed.

The proposed method is used to investigate complex crack evolution in mesoscale cementitious composite, which consists of aggregates, matrix and void pores. From a mesoscale point of view, it is found that cracks prefer to evolve within the matrix phase. As a crack encounters an aggregate, it tends to bypass the aggregate and evolve along the interface. Cracks tend to avoid to penetrate through aggregates. Also, cracks tend to be attracted by void pores. From a mesoscale point of view, it is revealed that the elastic modulus and strength of concrete models are closely related to porosity.

A criterion with a damage threshold is introduced to the proposed method. The criterions with and without a damage threshold are compared with each other in details. The proposed method is proven to be a useful tool to study mechanical behavior and crack evolution of brittle multiphase composites.

This paper presents a novel mesoscale RF (mRF) relay that integrates advanced high resolution stereolithography (SL) and micro wire electro discharge machining (μEDM) technologies. Methods and infrastructure for reliable batch assembly of electromechanical actuators and structural parts less than 5 mm³ in volume are described. Switches made using these techniques are expected to have greater power handling capability relative to current micro RF relay products.

The conjecture is that the integration of SL and similar rapid additive manufacturing with other mesofabrication technologies can yield innovative miniature products with novel capabilities. A series of mRF prototypes consisting of a contact mechanism and actuator with return spring were fabricated assembled, inspected, and characterized for electromechanical performance. Characterization results led to specific conclusions regarding capabilities of the mRF product, and the integrated manufacturing technique.

The microassembly apparatus and epoxy‐based fastening system led to durable prototypes within 4 h (excluding a 16‐24 h cure cycle). Relay stroke ranged from 560 to 1,650 μm indicating a relative assembly accuracy of 90 percent. Prototypes demonstrated insertion loss of 1.3 dB at 100 MHz and isolation of better than 30 dB through 300 MHz.

Results indicated that fully functional and robust mesoscale relays are possible using integrated manufacturing with SL. However, prototypes exhibited high contact resistance and lacked assembly precision in the context of contact mechanism stroke. Opportunities exist to reduce contact resistance and switching time.

The research provides a practical new product application for integrated mesoscale rapid manufacturing.

This work represents one of the first examples of a mesoscale relay rapidly manufactured with a combination of μEDM and SL components.

Mesoscale air quality models are an important tool to forecast and analyse the air quality in regional and urban areas. In recent years an increased interest has been shown by decision makers in these types of software tools. The complexity of such a model has grown exponentially with the increase of computer power. Nowadays, medium workstations can run operational versions of these modelling systems successfully. Presents a complex mesoscale air quality model which has been installed in the Environmental Office of the Madrid community (Spain) in order to forecast accurately the ozone, nitrogen dioxide and sulphur dioxide air concentrations in a 3D domain centred on Madrid city. Describes the challenging scientific matters to be solved in order to develop an operational version of the atmospheric mesoscale numerical pollution model for urban and regional areas (ANA). Some encouraging results have been achieved in the attempts to improve the accuracy of the predictions made by the version already installed.

Confronting the unveiled sophisticated structural and physical characteristics of permanent magnets, notably the samarium–cobalt (Sm-Co) alloy, This work aims to introduce a simulation scheme that can link physics-based micromagnetics on the nanostructures and magnetostatic homogenization on the mesoscale polycrystalline structures.

The simulation scheme is arranged in a multiscale fashion. The magnetization behaviors on the nanostructures examined with various orientations are surrogated as the micromagnetic-informed hysterons. The hysteresis behavior of the mesoscale polycrystalline structures with micromagnetic-informed hysterons is then evaluated by computational magnetostatic homogenization.

The micromagnetic-informed hysterons can emulate the magnetization reversal of the parameterized Sm-Co nanostructures as the local hysteresis behavior on the mesostructures. The simulation results of the mesoscale polycrystal demonstrate that the demagnetization process starts from the grain with the largest orientation angle (a) and then propagates to the surrounding grains.

The presented scheme depicts the demand for integrating data-driven methods, as the parameters of the surrogate hysteron intrinsically depend on the nanostructure and its orientation. Further hysteron parameters that help the surrogate hysteron emulate the micromagnetic-simulated magnetization reversal should be examined.

This work provides a novel multiscale scheme for simulating the polycrystalline permanent magnets’ hysteresis while recapitulating the nanoscale mechanisms, such as the nucleation of domains, and domain wall migration and pinning. This scheme can be further extended to simulate the part-level hysteresis considering the mesoscale features.

The purpose of this paper is the numerical assessment of concrete behaviour close to failure, via the development of robust elastoplastic models inclusive of damage effects. If mesoscale investigations are to be considered, the model must take into account the local confinement effects because of the presence of aggregate inclusions in the cement paste and, correspondingly, the possibility to account for local 3D stress states even under uniaxial compression. Additionally, to enhance the predictive capabilities of a mesoscale representation, the reconstructed geometry must accurately follow the real one.

The work provides a procedure that combines a 3D digital image technique with finite element (FE) modelling thus maintaining the original 3D morphology of the composite.

The potentialities of the proposed approach are discussed, giving new insights to a FE modelling (FEM)-based approach applied together with a computer-aided design. Coupled mechanisms of mechanical mismatch and confinement, characterizing the combined cement matrix-aggregates effect, are captured and highlighted via the numerical tests.

The novelty of this research work lies in the proposal of a digitally based methodology for a precise concrete reconstruction together with the adoption of an upgraded elastic–plastic damage model for the cement paste.

This paper aims to establish a multiscale topology optimization method for the optimal design of non-periodic, self-supporting cellular structures subjected to thermo-mechanical loads. The result is a hierarchically complex design that is thermally efficient, mechanically stable and suitable for additive manufacturing (AM).

The proposed method seeks to maximize thermo-mechanical performance at the macroscale in a conceptual design while obtaining maximum shear modulus for each unit cell at the mesoscale. Then, the macroscale performance is re-estimated, and the mesoscale design is updated until the macroscale performance is satisfied.

A two-dimensional Messerschmitt Bolkow Bolhm (MBB) beam withstanding thermo-mechanical load is presented to illustrate the proposed design method. Furthermore, the method is implemented to optimize a three-dimensional injection mold, which is successfully prototyped using 420 stainless steel infiltrated with bronze.

By developing a computationally efficient and manufacturing friendly inverse homogenization approach, the novel multiscale design could generate porous molds which can save up to 30 per cent material compared to their solid counterpart without decreasing thermo-mechanical performance.

This study is a useful tool for the designer in molding industries to reduce the cost of the injection mold and take full advantage of AM.

A rapid prototyping process applying ceramic gelcasting and assembly mould shape deposition manufacturing has been developed to fabricate mesoscale silicon nitride components with complex 3D geometry. An overview of the fabrication of Si₃N₄ burner arrays for gas turbine reheat applications is demonstrated. The design of burner arrays features internal fuel passages and integrated fuel injection elements, which cannot be manufactured by conventional methods. Geometrical decomposition of design models and recent developments in ceramic processing provide a novel approach in prototyping the burner arrays. In this paper, issues of materials compatibility, mould fabrication strategies, ceramic processing, and design iterations will be discussed along with the functional test of the 4×4 burner array.

This paper aims to provide a comprehensive review of the state-of–the-art design methods for additive manufacturing (AM) technologies to improve functional performance.

In this survey, design methods for AM to improve functional performance are divided into two main groups. They are design methods for a specific objective and general design methods. Design methods in the first group primarily focus on the improvement of functional performance, while the second group also takes other important factors such as manufacturability and cost into consideration with a more general framework. Design methods in each groups are carefully reviewed with discussion and comparison.

The advantages and disadvantages of different design methods for AM are discussed in this paper. Some general issues of existing methods are summarized below: most existing design methods only focus on a single design scale with a single function; few product-level design methods are available for both products’ functionality and assembly; and some existing design methods are hard to implement for the lack of suitable computer-aided design software.

This study is a useful source for designers to select an appropriate design method to take full advantage of AM.

In this survey, a novel classification method is used to categorize existing design methods for AM. Based on this classification method, a comprehensive review is provided in this paper as an informative source for designers and researchers working in this field.