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The purpose of this study is to introduce a new concept in engineered materials and that is truss substructured materials (TSMs). These materials would be engineered to express mechanical abilities that are seldom found in nature.

This article starts with defining TSMs and how to classify and name TSMs. The article also introduces the theoretical modeling of TSMs, the software developed for analyzing TSMs and the parametric studies performed.

After these studies, new materials are introduced that have abilities such as negative Poisson ratio in X and Y direction, negative Poisson ratio in one direction (either x or y), self-remodeling under stress.

The research is done in 2D, further studies in 3D using 3D printing are required to make the suggested materials a viable real-world solution.

The main contribution of this research work is the proposed nomenclature that creates a system for researchers to experiment and create novel and unique versions of the proposed materials. Furthermore, some of the materials developed exhibit some unique properties that may create advances in engineering with further development.

Selective electron beam melting (SEBM) is one of the popular powder-bed additive manufacturing (AM) technologies. The purpose of this paper is to develop a simulation strategy for SEBM process to get data which are vital for realistic failure prediction and process parameters control for real complex components.

Focusing on the SEBM process of tantalum, this paper presents a three-dimensional thermo-mechanical modeling strategy based on ABAQUS and its subroutines. The simulation strategy used in this paper is developed for SEBM process of pure tantalum but could be extended to other AM fabrication technologies and other metals without difficulties.

The simulation of multi-track multi-layer SEBM process of tantalum was carried out to predict the temperature field, the molten pool evolution and the residual stress distribution. The key information such as inter-track molten pool overlapping ratio and inter-layer refusion state can be extracted from the obtained molten pool morphologies, which are vital for realistic failure prediction and process parameters control for real components. The authors finally demonstrate the capability of the strategy used by simulating a 2 mm × 2 mm × 10 mm lattice structure with total 200 layers.

The simulation of multi-track multi-layer SEBM process of tantalum was carried out. The key information such as inter-track molten pool overlapping ratio and inter-layer refusion state can be extracted. The authors finally demonstrate the capability of the strategy used by simulating a lattice structure. Not only temperature distribution but also stress evolution are captured. Our simulation strategy is developed for the SEBM process of pure tantalum, but it could be extended to other AM fabrication technologies and other metals without difficulties.