ß-Phase Enhancement of Force Spun Composite Nanofibers for Sensing Applications.

In this study, a piezoelectric harvesting device was developed using polyvinylidene fluoride (PVDF) nanofibers reinforced with either BaTiO3 nanoparticles or graphene powder. BaTiO3 nanoparticles were synthesized through the sol-gel method with an average size of approximately 32 nm. The PVDF nanofibers, along with the nanoparticle composites in an acetone-N,N-dimethylformamide mixture, were produced using a centrifugal Forcespinning™ machine, resulting in a heterogeneous arrangement of fiber meshes, with an average diameter of 1.6 µm. Experimental tests revealed that the electrical performance of the fabricated harvester reached a maximum value of 35.8 Voc, demonstrating the potential of BaTiO3/ PVDF-based piezoelectric devices for designing wearable applications such as body-sensing and energy-harvesting devices.

Magnetic and Viscoelastic Response of Magnetorheological Elastomers Based on a Combination of Iron Nano- and Microparticles.

In this paper, we discuss the creation of a hybrid magnetorheological elastomer that combines nano- and microparticles. The mixture contained 45 wt.% fillers, with combinations of either 0% nanoparticles and 100% microparticles or 25% nanoparticles and 75% microparticles. TGA and FTIR testing confirmed the materials' thermal and chemical stability, while an SEM analysis determined the particles' size and morphology. XRD results were used to determine the crystal size of both nano- and microparticles. The addition of reinforcing particles, particularly nanoparticles, enhanced the stiffness of the composite materials studied, but their overall strength was only minimally affected. The computed interaction parameter relative to the volume fraction was consistent with the previous literature. Furthermore, the study observed a magnetic response increment in composite materials reinforced with nanoparticles above 30 Hz. The isotropic material containing only microparticles had a lower storage modulus than the isotropic sample with nanoparticles without a magnetic field. However, when a magnetic field was applied, the material with only microparticles exhibited a higher storage modulus than the samples with nanoparticles.

Modeling the Ultrasonic Micro-Injection Molding Process Using the Buckingham Pi Theorem.

Dimensional analysis through the Buckingham Pi theorem was confirmed as an efficient mathematical tool to model the otherwise non-linear high order ultrasonic micro-injection molding process (UMIM). Several combinations of processing conditions were evaluated to obtain experimental measurements and validate the derived equations. UMIM processing parameters, output variable energy consumption, and final specimen's Young modulus were arranged in dimensionless groups and formulated as functional relationships, which lead to dimensionless equations that predict output variables as a function of the user-specified processing parameters and known material properties.

Inducing Magnetic Properties with Ferrite Nanoparticles in Resins for Additive Manufacturing.

Additive manufacturing and nanotechnology have been used as fundamental tools for the production of nanostructured parts with magnetic properties, expanding the range of applications in additive processes through tank photopolymerization. Magnetic cobalt ferrite (CoFe2O4) and barium ferrite (BaFe12O19) nanoparticles (NPs) with an average size distribution value (DTEM) of 12 ± 2.95 nm and 37 ± 12.78 nm, respectively, were generated by the hydroxide precipitation method. The dispersion of the NPs in commercial resins (Anycubic Green and IRIX White resin) was achieved through mechanochemical reactions carried out in an agate mortar for 20 min at room temperature, with limited exposure to light. The resulting product of each reaction was placed in amber vials and stored in a box to avoid light exposure. The photopolymerization process was carried out only at low concentrations (% w/w NPs/resin) since high concentrations did not result in the formation of pieces, due to the high refractive index of ferrites. The Raman spectroscopy of the final pieces showed the presence of magnetic NPs without any apparent chemical changes. The electron paramagnetic resonance (EPR) results of the pieces demonstrated that their magnetic properties were maintained and not altered during the photopolymerization. Although significant differences were observed in the dispersion process of the NPs in each piece, we determined that the photopolymerization did not affect the structure and superparamagnetic behavior of ferrite NPs during processing, successfully transferring the magnetic properties to the final 3D-printed piece.

Polypropylene-Based Polymer Locking Ligation System Manufacturing by the Ultrasonic Micromolding Process.

In recent years, there has been a growing demand for biocompatible medical devices on the microscale. However, the manufacturing of certain microfeatures has posed a significant challenge. To address this limitation, a new process called ultrasonic injection molding or ultrasonic molding (USM) has emerged as a potential solution. In this study, we focused on the production of a specific microdevice known as Hem-O-Lok, which is designed for ligation and tissue repair during laparoscopic surgery. Utilizing USM technology, we successfully manufactured the microdevice using a nonabsorbable biopolymer that offers the necessary flexibility for easy handling and use. To ensure high-quality microdevices, we extensively investigated various processing parameters such as vibration amplitude, temperature, and injection velocity. Through careful experimentation, we determined that the microdevice achieved optimal quality when manufactured under conditions of maximum vibrational amplitude and temperatures of 50 and 60 °C. This conclusion was supported by measurements of critical microfeatures. Additionally, our materials characterization efforts revealed the presence of a carbonyl (C=O) group resulting from the thermo-oxidation of air in the plasticizing chamber. This finding contributes to the enhanced thermal stability of the microdevices within a temperature range of 429-437 °C.

A Novel Approach for Optimization of Soft Material Constitutive Model Parameters Based on a Genetic Algorithm and Drucker's Stability Criterion.

The growing interest in soft materials to develop flexible devices involves the need to create accurate methodologies to determine parameter values of constitutive models to improve their modeling. In this work, a novel approach for the optimization of constitutive model parameters is presented, which consists of using a genetic algorithm (GA) to obtain a set of solutions from data of uniaxial tensile tests, which are later used to simulate the mechanical test using finite element analysis (FEA) software to find an optimal solution considering Drucker's stability criterion. This approach was applied to the elastomer Ecoflex 00-30 considering the Warner and Yeoh models and Rivlin's phenomenological theory. The correlation between the experimental and the predicted data by the models was determined using the root mean squared error (RMSE), where the found parameter sets provided a close fit to the experimental data with RMSE values of 0.022 (ANSYS) and 0.024 (ABAQUS) for Warner's model, while for Yeoh's model were 0.014 (ANSYS) and 0.012 (ABAQUS). It was found that the best parameter values accurately follow the experimental material behavior using FEA. The proposed GA not only optimizes the material parameters but also has a high reproducibility level with average RMSE values of 0.024 for Warner's model and 0.009 for Yeoh's model, fulfilling Drucker's stability criterion.

Toward the Industrial Application of Aluminum-Based Nanocomposite Material: A Study of Zn-Plating Process in Circuit Breaker Application.

This article explores the industrial application of an Al-based nanocomposite reinforced with 0.5 wt.% of multiwalled carbon nanotubes with a Zn mechanical plating applied to fulfill the field requirements of electrical devices. The performance of electric devices made from this nanocomposite material and with a Zn plating was compared with that of MCCB devices using a normal Cu compound. MCCB devices with the Al-based nanocomposites compound showed a better performance, with less heat generated due to a flow of electrical charge passing through the device. The presence of MWCNTs in the Al nanocomposite dissipates heat, maintaining a stable electrical resistance in the MCCB, in contrast to what happens with Cu compound, which increases its electrical resistance as the temperature in the device increases.

Soft Tissue Hybrid Model for Real-Time Simulations.

In this article, a recent formulation for real-time simulation is developed combining the strain energy density of the Spring Mass Model (SMM) with the equivalent representation of the Strain Energy Density Function (SEDF). The resulting Equivalent Energy Spring Model (EESM) is expected to provide information in real-time about the mechanical response of soft tissue when subjected to uniaxial deformations. The proposed model represents a variation of the SMM and can be used to predict the mechanical behavior of biological tissues not only during loading but also during unloading deformation states. To assess the accuracy achieved by the EESM, experimental data was collected from liver porcine samples via uniaxial loading and unloading tensile tests. Validation of the model through numerical predictions achieved a refresh rate of 31 fps (31.49 ms of computation time for each frame), achieving a coefficient of determination R2 from 93.23% to 99.94% when compared to experimental data. The proposed hybrid formulation to characterize soft tissue mechanical behavior is fast enough for real-time simulation and captures the soft material nonlinear virgin and stress-softened effects with high accuracy.

Influence of Epoxy Resin Curing Kinetics on the Mechanical Properties of Carbon Fiber Composites.

In this study, the kinetic parameters belonging to the cross-linking process of a modified epoxy resin, Aerotuf 275-34™, were investigated. Resin curing kinetics are crucial to understanding the structure-property-processing relationship for manufacturing high-performance carbon-fiber-reinforced polymer composites (CFRPCs). The parameters were obtained using differential scanning calorimetry (DSC) measurements and the Flynn-Wall-Ozawa, Kissinger, Borchardt-Daniels, and Friedman approaches. The DSC thermograms show two exothermic peaks that were deconvoluted as two separate reactions that follow autocatalytic models. Furthermore, the mechanical properties of produced carbon fiber/Aerotuf 275-34™ laminates using thermosetting polymers such as epoxies, phenolics, and cyanate esters were evaluated as a function of the conversion degree, and a close correlation was found between the degree of curing and the ultimate tensile strength (UTS). We found that when the composite material is cured at 160 °C for 15 min, it reaches a conversion degree of 0.97 and a UTS value that accounts for 95% of the maximum value obtained at 200 °C (180 MPa). Thus, the application of such processing conditions could be enough to achieve good mechanical properties of the composite laminates. These results suggest the possibility for the development of strategies towards manufacturing high-performance materials based on the modified epoxy resin (Aerotuf 275-34™) through the curing process.

Study of the Evolution of the Plastic Zone and Residual Stress in a Notched T-6061 Aluminum Sample.

Using experimental measurements and numerical computations, this paper focuses on studying the evolution of the plastic zone and how the residual stresses change in a notched T-6061 aluminum sample. Before the crack initiation, digital image measurements were taken to visualize the evolution of the plastic zone. After the sample was fractured, the material microstructure and the residual stresses around the cracked zone were characterized through optical microscopy and X-ray diffractometry. This article describes in detail how the plastic zone evolved around the notch before the crack initiation and shows the close agreement between experimental and numerical data during the load increment. The surface residual stress values around the tip of the notched sample were also measured and computed to give a better understanding of the affected region during the fracture process.

Spark Plasma Sintering of Aluminum Nanocomposite Powders: Recent Strategy to Translate from Lab-Scale to Mass Production.

The aim of this paper focuses on presenting a recent study that describes the fundamental steps needed to effectively scale-up from lab to mass production parts produced from Al powders reinforced with 0.5 wt% of industrial multiwalled carbon nanotubes (MWCNTs), with mechanical and electrical conductivity properties higher that those measured at the lab scale. The produced material samples were produced via a Spark Plasma Sintering (SPS) process using nanocomposite aluminum powders elaborated with a planetary ball-mill at the lab scale, and high-volume attrition milling equipment in combination with controlled atmosphere sinter hardening furnace equipment, which were used to consolidate the material at the industrial level. Surprisingly, the electrical conductivity and mechanical properties of the samples produced with the reinforced nanocomposite Al powders were made with mass production equipment and were similar or higher than those samples fabricated using metallic powders prepared with ball-mill lab equipment. Experimental measurements show that the hardness and the electrical conductivity properties of the samples fabricated with the mass production Al powders are 48% and 7.5% higher than those of the produced lab samples. This paper elucidates the steps that one needs to follow during the mass production process of reinforced aluminum powders to improve the physical properties of metallic samples consolidated via the SPS process.

Study of Friction and Wear Effects in Aluminum Parts Manufactured via Single Point Incremental Forming Process Using Petroleum and Vegetable Oil-Based Lubricants.

This paper focuses on studying how mineral oil, sunflower, soybean, and corn lubricants influence friction and wear effects during the manufacturing of aluminum parts via the single point incremental forming (SPIF) process. To identify how friction, surface roughness, and wear change during the SPIF of aluminum parts, Stribeck curves were plotted as a function of the SPIF process parameters such as vertical step size, wall angle, and tool tip semi-spherical diameter. Furthermore, lubricant effects on the surface of the formed parts are examined by energy dispersive spectroscopy (EDS) and scanning electron microscope (SEM) images, the Alicona optical 3D measurement system, and Fourier-transform infrared spectroscopy (FTIR). Results show that during the SPIF process of the metallic specimens, soybean and corn oils attained the highest friction, along forces, roughness, and wear values. Based on the surface roughness measurements, it can be observed that soybean oil produces the worst surface roughness finish in the direction perpendicular to the tool passes (Ra =1.45 µm) considering a vertical step size of 0.25 mm with a 5 mm tool tip diameter. These findings are confirmed through plotting SPIFed Stribeck curves for the soybean and corn oils that show small hydrodynamic span regime changes for an increasing sample step-size forming process. This article elucidates the effects caused by mineral and vegetable oils on the surface of aluminum parts produced as a function of Single Point Incremental Sheet Forming process parameters.

Enhanced Mathematical Model for Producing Highly Dense Metallic Components through Selective Laser Melting.

In this work, a previously developed mathematical model to predict bulk density of SLMed (produced via Selective Laser Melting) component is enhanced by taking laser power, scanning speed, hatch spacing, powder's thermal conductivity and specific heat capacity as independent variables. Experimental data and manufacturing conditions for the selective laser melting (SLM) of metallic materials (which include aluminum, steel, titanium, copper, tungsten and nickel alloys) are adapted from the literature and used to evaluate the validity of the proposed enhanced model. A strong relation between dependent and independent dimensionless products is observed throughout the studied materials. The proposed enhanced mathematical model shows to be highly accurate since the computed root-mean-square-error values (RMSE) does not exceed 5 × 10-7. Furthermore, an analytical expression for the prediction of bulk density of SLMed components was developed. From this, an expression for determining the needed scanning speed, with respect to laser power, to achieve highly dense components produced via SLM, is derived.

Influence of the Epoxy Resin Process Parameters on the Mechanical Properties of Produced Bidirectional [±45°] Carbon/Epoxy Woven Composites.

This work focuses on investigating the curing process of an epoxy-based resin-Aerotuf 275-34TM, designed for aerospace applications. To study the curing degree of Aerotuf 275-34TM under processing conditions, woven carbon fiber fabric (WCFF)/Aerotuf 275-34TM composite laminates were produced by compression molding using different processing temperatures (110, 135, 160, and 200 °C) during 15 and 30 min. Then, the mechanical behavior of the composite laminates was evaluated by tensile tests and correlated to the resin curing degree through Fourier-transform infrared spectroscopy (FTIR) analysis. The results show the occurrence of two independent reactions based on the consumption of epoxide groups and maleimide (MI) double bonds. In terms of epoxide groups, a conversion degree of 0.91 was obtained for the composite cured at 160 °C during 15 min, while the measured tensile properties of [±45°] WCFF/Aerotuf 275-34TM laminates confirmed that these epoxy resin curing processing conditions lead to an enhancement of the composite mechanical properties.

Enhancement of Electrical Conductivity of Aluminum-Based Nanocomposite Produced by Spark Plasma Sintering.

This article focuses on exploring how the electrical conductivity and densification properties of metallic samples made from aluminum (Al) powders reinforced with 0.5 wt % concentration of multi-walled carbon nanotubes (MWCNTs) and consolidated through spark plasma sintering (SPS) process are affected by the carbon nanotubes dispersion and the Al particles morphology. Experimental characterization tests performed by scanning electron microscopy (SEM) and by energy dispersive spectroscopy (EDS) show that the MWCNTs were uniformly ball-milled and dispersed in the Al surface particles, and undesirable phases were not observed in X-ray diffraction measurements. Furthermore, high densification parts and an improvement of about 40% in the electrical conductivity values were confirmed via experimental tests performed on the produced sintered samples. These results elucidate that modifying the powder morphology using the ball-milling technique to bond carbon nanotubes into the Al surface particles aids the ability to obtain highly dense parts with increasing electrical conductivity properties.

A Mathematical Dimensional Model for Predicting Bulk Density of Inconel 718 Parts Produced by Selective Laser Melting.

In this work, dimensional analysis is used to develop a general mathematical model to predict bulk density of SLMed components taking volumetric energy density, scanning speed, powder's thermal conductivity, specific heat capacity, and average grain diameter as independent variables. Strong relation between dependent and independent dimensionless products is observed. Inconel 718 samples were additively manufactured and a particular expression, in the form of a power-law polynomial, for its bulk density, in the working domain of the independent dimensionless product, was obtained. It is found that with longer laser exposure time, and lower scanning speed, better densification is attained. Likewise, volumetric energy density has a positive influence on bulk density. The negative effect of laser power in bulk density is attributed to improper process conditions leading to powder particle sublimation and ejection. A maximum error percentage between experimental and predicted bulk density of 3.7119% is achieved, which corroborates the accuracy of our proposed model. A general expression for determining the scanning speed, with respect to laser power, needed to achieve highly dense components, was derived. The model's applicability was further validated considering SLMed samples produced by AlSi10Mg and Ti6Al4V alloys. This article elucidates how to tune relevant manufacturing parameters to produce highly dense SLM parts using mathematical expressions derived from Buckingham's π- theorem.

Spark Plasma Sintering of Aluminum-Based Powders Reinforced with Carbon Nanotubes: Investigation of Electrical Conductivity and Hardness Properties.

This paper focuses on reporting results obtained by the spark plasma sintering (SPS) consolidation and characterization of aluminum-based nanocomposites reinforced with concentrations of 0.5 wt%, 1 wt% and 2 wt% of single-walled carbon nanotubes (SWCNTs) and multi-walled carbon nanotubes (MWCNTs). Experimental characterization performed by SEM shows uniform carbon nanotube (CNT) dispersion as well as carbon clusters located in the grain boundary of the Al matrix. The structural analysis and crystallite size calculation were performed by X-ray diffraction tests, detecting the characteristic CNT diffraction peak only for the composites reinforced with MWCNTs. Furthermore, a considerable increment in the crystallite size value for those Al samples reinforced and sintered with 1 wt% of CNTs was observed. Hardness tests show an improvement in the composite surface hardness of about 11% and 18% for those samples reinforced with 2 wt% of SWNCTs and MWCNTs, respectively. Conductivity measurements show that the Al samples reinforced with 2 wt% of MWCNTs and with 0.5 wt% SWCNTs reach the highest IACS values of 50% and 34%, respectively.

Investigation of the Mechanical Properties of Parts Fabricated with Ultrasonic Micro Injection Molding Process Using Polypropylene Recycled Material.

This research focuses on investigating how physical and mechanical properties of polypropylene (PP) recycled material are modified when ultrasonic micro injection molding (UMIM) technology is used to produce material specimens. Experimental characterization by differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), Fourier transform infrared (FTIR) spectra, and rheology tests show that the fabricated PP samples were able to withstand up to five times recycled processing before some signs of mechanical and physical properties degradation are observed. Surprisingly, uniaxial extension tests show an increase of 3.07%, 10.97% and 27.33% for Young's modulus, yield stress and ultimate stress values, respectively, and a slight reduction of 1.29% for the samples elongation at break when compared to the experimental data collected from virgin material samples. The improvement of these mechanical properties in the recycled samples suggests that ultrasonic microinjection produces a mechano-chemical material change.

Investigating the Mullins Effect and Energy Dissipation in Magnetorheological Polyurethane Elastomers.

The aim of this article was to investigate the mechanical performance of magnetorheological polyurethane elastomers reinforced with different concentrations of carbonyl iron microparticles (CIPs) in which stress softening, energy dissipation, residual strains, microparticles orientation, and magnetic flux density effects will be considered. Other aspects, such as the determination of the dissipated energy during cyclic loading and unloading, were investigated by considering a pseudo-elastic network model that takes into account residual strains, magnetic field intensity, and the isotropic and anisotropic material behavior. Theoretical predictions confirmed that the material shear modulus becomes sensitive not only for higher concentrations of CIPs added into the elastomer material matrix, but also to the magnetic flux intensity that induces attractive forces between CIPs and to the strong bonds between these and the elastomer matrix. It was also found that the addition of CIPs when embedded into the polymer matrix with a predefined orientation enhances the material shear modulus as well as its capacity to dissipate energy when subjected to magnetic flux density in loading and unloading directions.

Investigation of the Effect of Carbonyl Iron Micro-Particles on the Mechanical and Rheological Properties of Isotropic and Anisotropic MREs: Constitutive Magneto-Mechanical Material Model.

This article focuses on evaluating the influence that the addition of carbonyl iron micro-particles (CIPs) and its alignment have on the mechanical and rheological properties for magnetorheological elastomers (MREs) fabricated using polydimethylsiloxane (PDMS) elastomer, and 24 wt % of silicone oil (SO). A solenoid device was designed and built to fabricate the corresponding composite magnetorheological material and to perform uniaxial cyclic tests under uniform magnetic flux density. Furthermore, a constitutive material model that considers both elastic and magnetic effects was introduced to predict stress-softening and permanent set effects experienced by the MRE samples during cyclic loading tests. Moreover, experimental characterizations via Fourier transform infrared (FTIR), X-ray diffraction (XRD), tensile mechanical testing, and rheological tests were performed on the produced MRE samples in order to assess mechanical and rheological material properties such as mechanical strength, material stiffness, Mullins and permanent set effects, damping ratio, stiffness magnetorheological effect (SMR), and relative magnetorheological storage and loss moduli effects. Experimental results and theoretical predictions confirmed that for a CIPs concentration of 70 wt %, the material samples exhibit the highest shear modulus, stress-softening effects, and engineering stress values when the samples are subject to a maximum stretch value of 1.64 and a uniform magnetic flux density of 52.2 mT.