Residual Stresses in Surgical Growing Rods.

The treatment of early onset scoliosis using surgical growing rods suffers from high failure rate. Fatigue resistance can be improved by inducing compressive residual stresses within the near surface region. An in-depth investigation of the residual stresses profile evolution is performed through the sequence of material processing steps followed by surgeons handling operations, in connection to material properties. The final goal is to guide further improvements of growing rod lifetime. Residual stress evaluation was carried out on Ti-6Al-4V rods using digital image correlation applied to microbeam ring-core milling by focused ion beam. This provided experimental stress profiles in shot-peened rods before and after bending and demonstrated that compressive residual stresses are maintained at both concave and convex rod sides. A finite element model using different core and skin conditions was validated by comparison to experiments. The combination of an initial shot peening profile associated with a significant level of backstress was found to primarily control the generation of compressive stresses at the rod surface after bending. Guidelines to promote larger compressive stresses at the surface were formulated based on a parametric analysis. The analysis revealed the first order impact of the initial yield strength, kinematic hardening parameters and intensity of the shot peening operation, while the bending angle and the depth of shot peening stresses were found to be of minor importance. Materials exhibiting large kinematic hardening and low yield strength should be selected in order to induce compressive residual stresses at key fatigue initiation site.

Eco-Friendly Blends of Recycled PET Copolymers with PLLA and Their Composites with Chopped Flax Fibres.

The structure and properties of blends of a novel polyethylene terephthalate copolymer (COPET) obtained by chemical recycling of commercial PET with high-molar-mass poly-L-lactide (PLLA) are investigated and compared to corresponding composites with chopped flax fibres. The focus is on the morphology at nano- and micro-scales, on the thermal characteristics and on the mechanical behaviour. The blends are immiscible, as evidenced by virtually unchanged glass transition temperatures of the blend components compared to the neat polymers (49 °C for COPET and 63 °C for PLLA by DSC). At low PLLA content, the blends display a sea-island morphology with sub-micron to micron droplet sizes. As the composition approaches 50/50, the morphology transitions to a coarser co-continuous elongated structure. The blends and composites show strongly improved stiffness compared to COPET above its glass transition temperature, e.g., from melt behaviour at 60 °C for COPET alone to almost 600 MPa for the 50/50 blend and 500 MPa for the 20% flax composite of the 80/20 COPET/PLLA blend. The flax fibres increase the crystallisation rate of PLLA in blends with dispersed PLLA morphology. The evidence of cavitation on the fracture surfaces of blends shows that despite the immiscibility of the components, the interfacial adhesion between the phases is excellent. This is attributed to the presence of aliphatic ester spacers in COPET. The tensile strength of the 80/20 blend is around 50 MPa with a Young's modulus of 2250 MPa. The corresponding 20% flax composite has similar tensile strength but a high Young's modulus equal to 6400 MPa, which results from the individual dispersion and strong adhesion of the flax fibres and leads close to the maximum possible reinforcement of the composite, as demonstrated by tensile tests and nano-indentation. The Ashby approach to eco-selection relying on the embodied energy (EE) further clarifies the eco-friendliness of the blends and their composites, which are even better positioned than PLLA in a stiffness versus EE chart.

Integrated Approach to Eco-Friendly Thermoplastic Composites Based on Chemically Recycled PET Co-Polymers Reinforced with Treated Banana Fibres.

A major societal issue of disposal and environmental pollution is raised by the enormous and fast-growing production of single-use polyethylene terephthalate (PET) bottles, especially in developing countries. To contribute to the problem solution, an original route to recycle PET in the form of value-added environmentally friendly thermoplastic composites with banana fibres (Musa acuminata) has been developed at the laboratory scale. Banana fibres are a so far undervalued by-product of banana crops with great potential as polymer reinforcement. The melt-processing constraints of commercial PET, including used bottles, being incompatible with the thermal stability limits use of natural fibres; PET has been modified with bio-sourced reactants to produce co-polymers with moderate processing temperatures below 200 °C. First, commercial PET were partially glycolyzed with 1.3-propanediol to produce co-oligomers of about 20 repeating units, which were next chain extended with succinic anhydride and post-treated in a very unusual "soft solid state" process at temperatures in the vicinity of the melting point to generate co-polymers with excellent ductility. The molar mass build-up reaction is dominated by esterification of the chain ends and benefits from the addition of succinic anhydride to rebalance the acid-to-hydroxyl end-group ratio. Infra-red spectroscopy and intrinsic viscosity were extensively used to quantify the concentration of chain ends and the average molar mass of the co-polymers at all stages of the process. The best co-polymers are crystallisable, though at slow kinetics, with a Tg of 48 °C and a melting point strongly dependent upon thermal history. The composites show high stiffness (4.8 GPa at 20% fibres), consistent with the excellent dispersion of the fibres and a very high interfacial cohesion. The strong adhesion can be tentatively explained by covalent bonding involving unreacted succinic anhydride in excess during solid stating. A first approach to quantify the sustainable benefits of this PET recycling route, based on a rational eco-selection method, gives promising results since the composites come close to low-end wood materials in terms of the stiffness/embodied energy balance. Moreover, this approach can easily be extended to many other natural fibres. The present study is limited to a proof of concept at the laboratory scale but is encouraging enough to warrant a follow-up study toward scale-up and application development.

Point defect clusters and dislocations in FIB irradiated nanocrystalline aluminum films: an electron tomography and aberration-corrected high-resolution ADF-STEM study.

Focused ion beam (FIB) induced damage in nanocrystalline Al thin films has been characterized using advanced transmission electron microscopy techniques. Electron tomography was used to analyze the three-dimensional distribution of point defect clusters induced by FIB milling, as well as their interaction with preexisting dislocations generated by internal stresses in the Al films. The atomic structure of interstitial Frank loops induced by irradiation, as well as the core structure of Frank dislocations, has been resolved with aberration-corrected high-resolution annular dark-field scanning TEM. The combination of both techniques constitutes a powerful tool for the study of the intrinsic structural properties of point defect clusters as well as the interaction of these defects with preexisting or deformation dislocations in irradiated bulk or nanostructured materials.

Synergy between Phenoxy and CSR Tougheners on the Fracture Toughness of Highly Cross-Linked Epoxy-Based Composites.

A remarkable synergistic increase in fracture toughness by 130% is demonstrated for a CFRP high performance epoxy composite when adding an equal weight combination of phenoxy thermoplastic and core-shell rubber (CSR) toughening agents, as compared to a single toughener at a comparable total concentration of around 10 wt%. The dual-toughened matrix exhibits an unusual morphological arrangement of the two toughener agents. The interlaminar shear strength of the composites is also synergistically improved by about 75% as compared to the reference while the compression modulus reduction and viscosity increase are significantly smaller than for the single phenoxy toughened system. A partial filtering of the CSR particles by the dense CF fabric during pre-pregging leads to a less than optimum CSR dispersion in the composites, showing that the synergy can be further optimized, possibly to the same level as the unreinforced systems.

Deciphering the interactions between single arm dislocation sources and coherent twin boundary in nickel bi-crystal.

The introduction of a well-controlled population of coherent twin boundaries (CTBs) is an attractive route to improve the strength ductility product in face centered cubic (FCC) metals. However, the elementary mechanisms controlling the interaction between single arm dislocation sources (SASs), often present in nanotwinned FCC metals, and CTB are still not well understood. Here, quantitative in-situ transmission electron microscopy (TEM) observations of these mechanisms under tensile loading are performed on submicron Ni bi-crystal. We report that the absorption of curved screw dislocations at the CTB leads to the formation of constriction nodes connecting pairs of twinning dislocations at the CTB plane in agreement with large scale 3D atomistic simulations. The coordinated motion of the twinning dislocation pairs due to the presence of the nodes leads to a unique CTB sliding mechanism, which plays an important role in initiating the fracture process at a CTB ledge. TEM observations of the interactions between non-screw dislocations and the CTB highlight the importance of the synergy between the repulsive force of the CTB and the back stress from SASs when the interactions occur in small volumes.

Fracture mechanisms in Ti and Co-Cr growing rods and impact on clinical practice.

The widely used treatment of early onset scoliosis based on fusionless spinal instrumentation with growing rods suffers from severe complications due to premature rod failure. Only few studies have explored the fracture mechanisms in single rod constructs, while clinical practice urgently needs guidance. The objectives of this study are (i) to determine the failure mechanisms in Ti-6Al-4V alloy, Ti Cp 2 and Co-Cr alloy rods, and (ii) to propose strategies to reduce the risk of rod fracture. For this purpose, seven rods from three patients treated for early onset scoliosis were characterized by preoperative, pre-fracture X-rays and after-fracture X-rays. Fracture surface analysis, performed using scanning electron microscopy, revealed similar failure mechanisms for all rods, independent of composition and diameter. Fracture is caused by fatigue, associated to repeated bending action in the anteroposterior direction. Cracking initiates at multiple sites. Three-point bending fatigue tests on Ti-6Al-4V bent rods confirmed the fracture scenario. A beam bending model indicates that the failure process is controlled by the combination of cyclic vertical and horizontal forces with amplitudes from 200 N to 400 N and from 70 N to 150 N, respectively. Strategies to minimize fracture involve adaptations of material properties and rod geometry to scoliosis characteristics, including sagittal alignment, and spine behavior.

Thickness and elastic modulus of plasma treated PDMS silica-like surface layer.

The adhesion of poly(dimethylsiloxane) (PDMS) rubber is largely improved by oxygen plasma surface treatment. The thickness of the silica-like surface layer is characterized by performing transmission electron microscopy imagery on microtome slices of welded plasma treated surfaces. The specific double layer contrast can be considered as equal to twice the thickness of the silica-like layer. The thickness measurements combined with strain-induced elastic buckling instability analysis gives an estimate of the elastic modulus of the silica-like layer equal to 1.5 GPa.

In Situ Quantitative Tensile Testing of Antigorite in a Transmission Electron Microscope.

The determination of the mechanical properties of serpentinites is essential toward the understanding of the mechanics of faulting and subduction. Here we present the first in situ tensile tests on antigorite in a transmission electron microscope. A push-to-pull deformation device is used to perform quantitative tensile tests, during which force and displacement are measured, while the evolving microstructure is imaged with the microscope. The experiments have been performed at room temperature on 2 × 1 × 0.2 µm3 beams prepared by focused ion beam. The specimens are not single crystals despite their small sizes. Orientation mapping indicated that several grains were well oriented for plastic slip. However, no dislocation activity has been observed even though the engineering tensile stress went up to 700 MPa. We show also that antigorite does not exhibit a purely elastic-brittle behavior since, despite the presence of defects, the specimens accumulate permanent deformation and did not fail within the elastic regime. Instead, we observe that strain localizes at grain boundaries. All observations concur to show that under these experimental conditions, grain boundary sliding is the dominant deformation mechanism. This study sheds a new light on the mechanical properties of antigorite and calls for further studies on the structure and properties of grain boundaries in antigorite and more generally in phyllosilicates.

Datasets for the analysis of dislocations at grain boundaries and during vein formation in cyclically deformed Ni micropillars.

The dataset together with the corresponding Python scripts and Jupyter notebooks presented in this article are supplementary data for the work presented in Samaee et al., 2019 [1]. The data itself consists of two parts: the simulation data that was used in [1] to analyze the effect of a particular grain boundary on curved dislocations and the precession electron diffraction (PED) strain maps together with post-processed data for analyzing details of the observed dislocation vein structures. Additionally, the complete stress tensor components, which are not shown in [1], have also been included. The data sets are accompanied by Python code explaining the file formats and showing how to post-process the data.

Atomic-scale viscoplasticity mechanisms revealed in high ductility metallic glass films.

The fundamental plasticity mechanisms in thin freestanding Zr65Ni35 metallic glass films are investigated in order to unravel the origin of an outstanding strength/ductility balance. The deformation process is homogenous until fracture with no evidence of catastrophic shear banding. The creep/relaxation behaviour of the films was characterized by on-chip tensile testing, revealing an activation volume in the range 100-200 Å3. Advanced high-resolution transmission electron microscopy imaging and spectroscopy exhibit a very fine glassy nanostructure with well-defined dense Ni-rich clusters embedded in Zr-rich clusters of lower atomic density and a ~2-3 nm characteristic length scale. Nanobeam electron diffraction analysis reveals that the accumulation of plastic deformation at room-temperature correlates with monotonously increasing disruption of the local atomic order. These results provide experimental evidences of the dynamics of shear transformation zones activation in metallic glasses. The impact of the nanoscale structural heterogeneities on the mechanical properties including the rate dependent behaviour is discussed, shedding new light on the governing plasticity mechanisms in metallic glasses with initially heterogeneous atomic arrangement.

Dislocation driven nanosample plasticity: new insights from quantitative in-situ TEM tensile testing.

Intrinsic dislocation mechanisms in the vicinity of free surfaces of an almost FIB damage-free single crystal Ni sample have been quantitatively investigated owing to a novel sample preparation method combining twin-jet electro-polishing, in-situ TEM heating and FIB. The results reveal that the small-scale plasticity is mainly controlled by the conversion of few tangled dislocations, still present after heating, into stable single arm sources (SASs) as well as by the successive operation of these sources. Strain hardening resulting from the operation of an individual SAS is reported and attributed to the decrease of the length of the source. Moreover, the impact of the shortening of the dislocation source on the intermittent plastic flow, characteristic of SASs, is discussed. These findings provide essential information for the understanding of the regime of 'dislocation source' controlled plasticity and the related mechanical size effect.

Proposal of Characterization Procedure of Metal⁻Graphite Interface Strength in Compacted Graphite Iron.

Compacted graphite iron is the material of choice for engine cylinder heads of heavy-duty trucks. Compacted graphite iron provides the best possible compromise between optimum mechanical properties, compared to flake graphite iron, and optimum thermal conductivity, compared to spheroidal graphite iron. The vermicular-shaped graphite particles, however, act as stress concentrators, and, as a result of delamination from the metal matrix, they are responsible for crack initiation during the thermomechanical fatigue cycles occurring through engine startup and shutdown cycles. Scratch tests driven over the matrix and into the graphite particles were performed in order to characterize the strength of the metal⁻graphite interface. Samples extracted from a cylinder head in as-cast condition were compared to samples subjected to a heat-treatment at 700 °C for 60 h. The former samples were composed of a primarily pearlitic matrix and graphite particles (~11.5 vol %), whereas, after annealing, a certain pearlite fraction decomposed into Fe and C, producing a microstructure with graphite⁻ferrite interfaces, exhibiting a partially spiky morphology. The scratch test revealed that the ferrite⁻graphite interfaces with spiky nature exhibited a stronger resistance to delamination compared to the ferrite⁻graphite interfaces with smooth morphology. One reason for the high interface strength is the mechanical interlocking between graphite spikes and ferrite, increasing the contact area between the two phases.

Kinked silicon nanowires-enabled interweaving electrode configuration for lithium-ion batteries.

A tri-dimensional interweaving kinked silicon nanowires (k-SiNWs) assembly, with a Ni current collector co-integrated, is evaluated as electrode configuration for lithium ion batteries. The large-scale fabrication of k-SiNWs is based on a procedure for continuous metal assisted chemical etching of Si, supported by a chemical peeling step that enables the reuse of the Si substrate. The kinks are triggered by a simple, repetitive etch-quench sequence in a HF and H2O2-based etchant. We find that the inter-locking frameworks of k-SiNWs and multi-walled carbon nanotubes exhibit beneficial mechanical properties with a foam-like behavior amplified by the kinks and a suitable porosity for a minimal electrode deformation upon Li insertion. In addition, ionic liquid electrolyte systems associated with the integrated Ni current collector repress the detrimental effects related to the Si-Li alloying reaction, enabling high cycling stability with 80% capacity retention (1695 mAh/gSi) after 100 cycles. Areal capacities of 2.42 mAh/cm2 (1276 mAh/gelectrode) can be achieved at the maximum evaluated thickness (corresponding to 1.3 mgSi/cm2). This work emphasizes the versatility of the metal assisted chemical etching for the synthesis of advanced Si nanostructures for high performance lithium ion battery electrodes.

Perfusion-decellularization of human ear grafts enables ECM-based scaffolds for auricular vascularized composite tissue engineering.

INTRODUCTION: Human ear reconstruction is recognized as the emblematic enterprise in tissue engineering. Up to now, it has failed to reach human applications requiring appropriate tissue complexity along with an accessible vascular tree. We hereby propose a new method to process human auricles in order to provide a poorly immunogenic, complex and vascularized ear graft scaffold. METHODS: 12 human ears with their vascular pedicles were procured. Perfusion-decellularization was applied using a SDS/polar solvent protocol. Cell and antigen removal was examined by histology and DNA was quantified. Preservation of the extracellular matrix (ECM) was assessed by conventional and 3D-histology, proteins and cytokines quantifications. Biocompatibility was assessed by implantation in rats for up to 60 days. Adipose-derived stem cells seeding was conducted on scaffold samples and with human aortic endothelial cells whole graft seeding in a perfusion-bioreactor. RESULTS: Histology confirmed cell and antigen clearance. DNA reduction was 97.3%. ECM structure and composition were preserved. Implanted scaffolds were tolerated in vivo, with acceptable inflammation, remodeling, and anti-donor antibody formation. Seeding experiments demonstrated cell engraftment and viability. CONCLUSIONS: Vascularized and complex auricular scaffolds can be obtained from human source to provide a platform for further functional auricular tissue engineered constructs, hence providing an ideal road to the vascularized composite tissue engineering approach. STATEMENT OF SIGNIFICANCE: The ear is emblematic in the biofabrication of tissues and organs. Current regenerative medicine strategies, with matrix from donor tissues or 3D-printed, didn't reach any application for reconstruction, because critically missing a vascular tree for perfusion and transplantation. We previously described the production of vascularized and cell-compatible scaffolds, from porcine ear grafts. In this study, we ---- applied findings directly to human auricles harvested from postmortem donors, providing a perfusable matrix that retains the ear's original complexity and hosts new viable cells after seeding. This approach unlocks the ability to achieve an auricular tissue engineering approach, associated with possible clinical translation.

A generic "micro-Stoney" method for the measurement of internal stress and elastic modulus of ultrathin films.

Accurate measurement of the mechanical properties of ultra-thin films with thicknesses typically below 100 nm is a challenging issue with an interest in many fields involving coating technologies, microelectronics, and MEMS. A bilayer curvature based method is developed for the simultaneous determination of the elastic mismatch strain and Young's modulus of ultra-thin films. The idea is to deposit the film or coating on very thin cantilevers in order to amplify the curvature compared to a traditional "Stoney" wafer curvature test, hence the terminology "micro-Stoney." The data reduction is based on the comparison of the curvatures obtained for different supporting layer thicknesses. The elastic mismatch strain and Young's modulus are obtained from curvature measurements of cantilevers before and after the film deposition. The data reduction scheme relies on both analytical and finite element calculations, depending on the magnitude of the curvature. The experimental validation has been performed on ultra-thin low pressure chemical vapor deposited silicon nitride films with thickness ranging between 54 and 133 nm deposited on silicon cantilevers. The technique is sensitive to the cantilever geometry, in particular, to the thickness ratio and width/thickness ratio. Therefore, the precision in the determination of the latter quantities determines the accuracy on the extracted elastic mismatch strain and elastic modulus. The method can be potentially applied to films as thin as a few nanometers.

Surface coating mediated swelling and fracture of silicon nanowires during lithiation.

Surface passivation of silicon anodes is an appealing design strategy for the development of reliable, high-capacity lithium-ion batteries. However, the structural stability of the coating layer and its influence on the lithiation process remain largely unclear. Herein, we show that surface coating mediates the swelling dynamics and the fracture pattern during initial lithiation of crystalline silicon nanopillars. We choose conformally nickel coated silicon architectures as a model system. Experimental findings are interpreted based on a chemomechanical model. Markedly different swelling and fracture regimes have been identified, depending on the coating thickness and silicon nanopillar diameter. Nanopillars with relatively thin coating display anisotropic swelling similar to pristine nanopillars, but with different preferred fracture sites. As the coating thickness increases, the mechanisms become isotropic, with one randomly oriented longitudinal crack that unzips the core-shell structure. The morphology of cracked pillars resembles that of a thin-film electrode on a substrate, which is more amenable to cyclic lithiation without fracture. The knowledge provided here helps clarify the cycling results of coated nanosilicon electrodes and further suggests design rules for better performance electrodes through proper control of the lithiation and fracture.

Overcurvature describes the buckling and folding of rings from curved origami to foldable tents.

Daily-life foldable items, such as popup tents, the curved origami sculptures exhibited in the Museum of Modern Art of New York, overstrained bicycle wheels, released bilayered microrings and strained cyclic macromolecules, are made of rings buckled or folded in tridimensional saddle shapes. Surprisingly, despite their popularity and their technological and artistic importance, the design of such rings remains essentially empirical. Here we study experimentally the tridimensional buckling of rings on folded paper rings, lithographically processed foldable microrings, human-size wood sculptures or closed arcs of Slinky springs. The general shape adopted by these rings can be described by a single continuous parameter, the overcurvature. An analytical model based on the minimization of the energy of overcurved rings reproduces quantitatively their shape and buckling behaviour. The model also provides guidelines on how to efficiently fold rings for the design of space-saving objects.

Note: fast and reliable fracture strain extraction technique applied to silicon at nanometer scale.

Simple fabrication process and extraction procedure to determine the fracture strain of monocrystalline silicon are demonstrated. Nanowires/nanoribbons in silicon are fabricated and subjected to uniaxial tensile stress along the complete length of the beams. Large strains up to 5% are measured for nanowires presenting a cross section of 50 nm × 50 nm and a length of 2.5 µm. An increase in fracture strain for silicon nanowires (NWs) with the downscaling of their volume is observed, highlighting the reduction of the defects probability as volume is decreased.