Functionality and Mechanical Performance of Miniaturized Non-Assembly Pin-Joints Fabricated in Ti6Al4V by Laser Powder Bed Fusion.

In this work, additively manufactured pin-joint specimens are analyzed for their mechanical performance and functionality. The functionality of a pin-joint is its ability to freely rotate. The specimens were produced using laser powder bed fusion technology with the titanium alloy Ti6Al4V. The pin-joints were manufactured using previously optimized process parameters to successfully print miniaturized joints with an angle to the build plate. The focus of this work lies in the influence of joint clearance, and therefore all specimens were manufactured with a variety of clearance values, from 0 µm up to 150 µm, in 10 µm steps. The functionality and performance were analyzed using torsion testing and tensile testing. Furthermore, a metallographic section was conducted to visually inspect the clearances of the additively manufactured pin-joints with different joint clearance values. The results of the torsion and tensile tests complement each other and emphasize a correlation between the joint clearance and the maximal particle size of the powder utilized for manufacturing and the mechanical behavior and functionality of the pin-joints. Non-assembly multibody pin-joints with good functionality were obtained reliably using a joint clearance of 90 µm or higher. Our findings show how and with which properties miniaturized pin-joints that can be integrated into lattice structures can be successfully manufactured on standard laser powder bed fusion machines. The results also indicate the potential and limitations of further miniaturization.

Miniaturization of Non-Assembly Metallic Pin-Joints by LPBF-Based Additive Manufacturing as Perfect Pivots for Pantographic Metamaterials.

This work introduced additively manufactured non-assembly, miniaturized pin-joints for pantographic metamaterials as perfect pivots. The titanium alloy Ti6Al4V was utilized with laser powder bed fusion technology. The pin-joints were produced using optimized process parameters required for manufacturing miniaturized joints, and they were printed at a particular angle to the build platform. Additionally, this process optimization will eliminate the requirement to geometrically compensate the computer-aided design model, allowing for even further miniaturization. In this work, pin-joint lattice structures known as pantographic metamaterials were taken into consideration. The mechanical behavior of the metamaterial was characterized by bias extension tests and cyclic fatigue experiments, showing superior levels of performance (no sign of fatigue for 100 cycles of an elongation of approximately 20%) in comparison to classic pantographic metamaterials made with rigid pivots. The individual pin-joints, with a pin diameter of 350 to 670 µm, were analyzed using computed tomography scans, indicating that the mechanism of the rotational joint functions well even though the clearance of 115 to 132 µm between the moving parts is comparable to the nominal spatial resolution of the printing process. Our findings emphasize new possibilities to develop novel mechanical metamaterials with actual moving joints on a small scale. The results will also support stiffness-optimized metamaterials with variable-resistance torque for non-assembly pin-joints in the future.

A Feasibility Study of In-Situ Damage Visualization in Basalt-Fiber Reinforced Polymers with Open-Source Digital Volume Correlation.

This work analyses damage formation within the bulk of basalt fiber-reinforced polymers (BFRP) by means of open-source Digital Volume Correlation (DVC). Volumetric image data were obtained from conventional in-situ X-Ray computed micro-tomography (µCT) of samples loaded in tension. The open-source image registration toolkit Elastix was employed to obtain full 3D displacement fields from the image data. We assessed the accuracy of the DVC results using the method of manufactured solution and showed that the approach followed here can detect deformation with a magnitude in the order of a fiber diameter which in the present case is 17 µm. The beneficial influence of regularization on DVC results is presented on the manufactured solution as well as on real in-situ tensile testing CT data of a BFRP sample. Results of the correlation showed that conventional µCT equipment in combination with DVC can be used to detect defects which could previously only be visualized using synchrotron facilities or destructive methods.

2D Numerical Simulation of Auxetic Metamaterials Based on Force and Deformation Consistency.

This work showcases a novel phenomenological method to create predictive simulations of metallic lattice structures. The samples were manufactured via laser powder bed fusion (LPBF). Simulating LPBF-manufactured metamaterials accurately presents a challenge. The printed geometry is different from the CAD geometry the lattice is based on. The reasons are intrinsic limitations of the printing process, which cause defects such as pores or rough surfaces. These differences result in material behavior that depends on the surface/volume ratio. To create predictive simulations, this work introduces an approach to setup a calibrated simulation based on a combination of experimental force data and local displacements obtained via global Digital Image Correlation (DIC). The displacement fields are measured via Finite Element based DIC and yield the true local deformation of the structure. By exploiting symmetries of the geometry, a simplified parametrized simulation model is created. The simulation is calibrated via Response Surface Methodology based on nodal displacements from FE-DIC combined with the experimental force/displacement data. This method is used to create a simulation of an anti-tetrachiral, auxetic structure. The transferability and accuracy are discussed, as well as the possible extension into 3D space.

Strain Acquisition Framework and Novel Bending Evaluation Formulation for Compression-Loaded Composites Using Digital Image Correlation.

Consistent and reproducible data are key for material characterization. This work presents digital image correlation (DIC) strain acquisition guidelines for compression-loaded carbon fiber composites. Additionally, a novel bending criterion is formulated which builds up on the DIC strain data so that it is able to completely replace state-of-the-art tactile strain devices. These guidelines are derived from a custom test setup that simultaneously investigates the front and side view of the specimen. They reflect both an observation and post-processing standpoint. It is found that the DIC-based strain progress matches closely with state-of-the-art strain gauges up to failure initiation. The new bending evaluation criterion allows the bending state-and therefore, the validity of the compression test-to be monitored analogously to the methodology defined in the standards. Furthermore, the new bending criterion eliminates a specific bending mode, caused by an offset of clamps, which cannot be detected by the traditional strain gauge-based monitoring approach.

Cluster analysis of seriously injured occupants in motor vehicle crashes.

Permanent monitoring of real-world crashes is important to identify injury patterns and injury mechanisms that still occur in the field despite existing regulations and consumer testing programs. This study investigates current injury patterns at the MAIS 3+ level in the accident environment without limiting the impact direction. The approach consisted of applying unsupervised clustering algorithms to NASS-CDS crash data in order to classify seriously injured, belted occupants into clusters based on injured body regions, biomechanical characteristics and crash severity. Injury patterns in each cluster were analyzed and associated with other characteristics of the crash, such as the collision configuration. The groups of seriously injured occupants found in this research contain a large amount of information and research possibilities. The resulting clusters represent new opportunities for vehicle safety, which have been highlighted in this study.

Injury patterns within clusters of seriously injured occupants comparing real-world crashes in the United States and the European Union.

OBJECTIVE: Crashworthiness assessments in the United States (U.S.) and the European Union (EU) include a large number of safety regulations and consumer testing programs. However, safety standards and testing procedures differ between the two regions. Not much research has been done in relation to this topic, because it has always been assumed that the accident environments in the U.S. and EU are not comparable. The objective of this study is to compare how vehicle occupants are severely injured in motor vehicle collisions in the U.S. and the EU by applying unsupervised learning to accident data. METHODS: A new methodology to identify clusters of seriously injured occupants in NASS-CDS was proposed by the authors in previous research. The current study goes one step further and uses the clusters to compare the injury patterns at the Maximum Abbreviated Injury Scale (MAIS) 3+ level of passenger vehicle occupants in the U.S. and German accident environments. The clustering model developed with NASS-CDS data is applied in this study to German In-Depth Accident Study (GIDAS) data. A machine learning algorithm automatically assigned each GIDAS case to its most similar NASS-CDS cluster controlling for nine different parameters. Those included the injury severity at the body region level, biomechanical characteristics of the occupants, and technical severity of the crash. RESULTS: Differences and analogies between GIDAS and NASS-CDS data within clusters of seriously injured occupants are highlighted. One of the clusters groups the collisions with the greatest mass incompatibility in NASS-CDS and GIDAS data. The injury patterns in the clusters that include elderly people match significantly between the U.S. and German data sets. The lack of younger population and elevated body mass index (BMI) values in the GIDAS sample make the injury patterns within these population groups less comparable than in the other clusters. CONCLUSIONS: Remarkably similar injury patterns at the MAIS 3+ level have been found in U.S. and German accident data sets after controlling for nine different parameters. This research provides evidence to indicate that how belted vehicle occupants are severely injured in the U.S. and in the EU is not necessarily different.

Improved specimen recovery in tensile split Hopkinson bar.

This paper presents an improved specimen recovery method for the tensile split Hopkinson bar (TSHB) technique. The method is based on the trapping of residual stress waves with the use of momentum trap bars. As is well known, successful momentum trapping in TSHB is highly sensitive to experimental uncertainties, especially on the incident bar side of the set-up. However, as is demonstrated in this paper, significant improvement in the reliability of specimen recovery is obtained by using two momentum trap bars in contact with the incident bar. This makes the trapping of the reflected wave insensitive to striker speed and removes the need for a precision set gap between the incident bar and the momentum trap.

Consistent temperature coupling with thermal fluctuations of smooth particle hydrodynamics and molecular dynamics.

We propose a thermodynamically consistent and energy-conserving temperature coupling scheme between the atomistic and the continuum domain. The coupling scheme links the two domains using the DPDE (Dissipative Particle Dynamics at constant Energy) thermostat and is designed to handle strong temperature gradients across the atomistic/continuum domain interface. The fundamentally different definitions of temperature in the continuum and atomistic domain - internal energy and heat capacity versus particle velocity - are accounted for in a straightforward and conceptually intuitive way by the DPDE thermostat. We verify the here-proposed scheme using a fluid, which is simultaneously represented as a continuum using Smooth Particle Hydrodynamics, and as an atomistically resolved liquid using Molecular Dynamics. In the case of equilibrium contact between both domains, we show that the correct microscopic equilibrium properties of the atomistic fluid are obtained. As an example of a strong non-equilibrium situation, we consider the propagation of a steady shock-wave from the continuum domain into the atomistic domain, and show that the coupling scheme conserves both energy and shock-wave dynamics. To demonstrate the applicability of our scheme to real systems, we consider shock loading of a phospholipid bilayer immersed in water in a multi-scale simulation, an interesting topic of biological relevance.

A review of computational methods in materials science: examples from shock-wave and polymer physics.

This review discusses several computational methods used on different length and time scales for the simulation of material behavior. First, the importance of physical modeling and its relation to computer simulation on multiscales is discussed. Then, computational methods used on different scales are shortly reviewed, before we focus on the molecular dynamics (MD) method. Here we survey in a tutorial-like fashion some key issues including several MD optimization techniques. Thereafter, computational examples for the capabilities of numerical simulations in materials research are discussed. We focus on recent results of shock wave simulations of a solid which are based on two different modeling approaches and we discuss their respective assets and drawbacks with a view to their application on multiscales. Then, the prospects of computer simulations on the molecular length scale using coarse-grained MD methods are covered by means of examples pertaining to complex topological polymer structures including star-polymers, biomacromolecules such as polyelectrolytes and polymers with intrinsic stiffness. This review ends by highlighting new emerging interdisciplinary applications of computational methods in the field of medical engineering where the application of concepts of polymer physics and of shock waves to biological systems holds a lot of promise for improving medical applications such as extracorporeal shock wave lithotripsy or tumor treatment.