In-Situ Monitoring of a Filament Wound Pressure Vessel by the MWCNT Sensor under Hydraulic Fatigue Cycling and Pressurization.

As a result of the high specific strength/stiffness to mass ratio, filament wound composite pressure vessels are extensively used to contain gas or fluid under pressure. The ability to in-situ monitor the composite pressure vessels for possible damage is important for high-pressure medium storage industries. This paper describes an in-situ monitoring method to permanently monitor composite pressure vessels for their structural integrity. The sensor is made of a multi-walled carbon nanotube (MWCNT) that can be embedded in the composite skin of the pressure vessels. The sensing ability of the sensor is firstly evaluated in various mechanical tests, and in-situ monitoring experiments of a full-scale composite pressure vessel during hydraulic fatigue cycling and pressurization are performed. The monitoring results of the MWCNT sensor are compared with the strains measured by the strain gauges. The results show that the measured signal by the developed sensor matches the mechanical behavior of the composite laminates under various load conditions. In the hydraulic fatigue test, the relationship between the resistance and the strain is built, and could be used to quantitative monitor the filament wound pressure vessel. The bursting of the pressure vessel can be detected by the sharp increase of the MWCNT sensor resistance. Embedding the MWCNT sensor into the composite pressure vessel is successfully demonstrated as a promising method for structural health monitoring.

Bioinspired Double-Broadband Switchable Microwave Absorbing Grid Structures with Inflatable Kresling Origami Actuators.

Tunable radar stealth structures are critical components for future military equipment because of their potential to further enhance the design space and performance. Some previous investigations have utilized simple origami structures as the basic adjusting components but failed to achieve the desired broadband microwave absorbing characteristic. Herein, a novel double-broadband switchable microwave absorbing grid structure has been developed with the actuators of inflatable Kresling origami structures. Geometric constraints are derived to endow a bistable feature with this origami configuration, and the stable states are switched by adjusting the internal pressure. An ultra-broadband microwave absorbing structure is proposed with a couple of complementary microwave stealth bands, and optimized by a particle swarm optimization algorithm. The superior electromagnetic performance results from the mode switch activating different absorbing components at corresponding frequencies. A digital adjusting strategy is applied, which effectively achieves a continuously adjusting effect. Further investigations show that the proposed structure possesses superior robustness. In addition, minimal interactions are found between adjacent grid units, and the electromagnetic performance is mainly related to the duty ratio of the units in different states. They have enhanced the microwave absorbing performance of grid structures through a tunable design, a provided a feasible paradigm for other tunable absorbers.

Crashworthy optimization of skeleton-filled FRP tubes based on back propagation neural network.

Lightweight composite tubes have been widely used in vehicle safety systems as energy absorbers. To improve the crashworthiness of tubes, composite skeletons with a variety of cross-sectional profiles were ingeniously designed as internal reinforcements. Herein, a novel composite skeleton comprising cross-ribs and an inner circle (OS-skeleton) was proposed and integrally fabricated through the special assembling molds. The novel OS-skeleton presented a steady progressive failure mode under dynamic impact loads, leading to remarkable material utilization and energy absorption characteristics. Subsequently, finite element analysis (FEA) models were developed. The predicted response curves and deformation modes were consistent with the experimental results. Finally, a multi-objective optimization utilizing the back propagation neural network (BPNN) was then conducted to further enhance the mean crushing force (MCF) and specific energy absorption (SEA) by adjusting several structural parameters. The results showed that MCF and SEA increased with the increasing thickness of the skeletons and the number of circumferential ribs. By comparison, the diameter of inner tube and the number of circumferential ribs showed a non-linear relationship with the energy absorption characteristics due to their combined effects. In sum, the proposed composite tubes filled with OS-skeletons could maximize certain aspects of crashworthiness performance through proper structural design, demonstrating great potential for lightweight energy absorbers.

Inverse Design of Energy-Absorbing Metamaterials by Topology Optimization.

Compared with the forward design method through the control of geometric parameters and material types, the inverse design method based on the target stress-strain curve is helpful for the discovery of new structures. This study proposes an optimization strategy for mechanical metamaterials based on a genetic algorithm and establishes a topology optimization method for energy-absorbing structures with the desired stress-strain curves. A series of structural mutation algorithms and design-domain-independent mesh generation method are developed to improve the efficiency of finite element analysis and optimization iteration. The algorithm realizes the design of ideal energy-absorbing structures, which are verified by additive manufacturing and experimental characterization. The error between the stress-strain curve of the designed structure and the target curve is less than 5%, and the densification strain reaches 0.6. Furthermore, special attention is paid to passive pedestrian protection and occupant protection, and a reasonable solution is given through the design of a multiplatform energy-absorbing structure. The proposed topology optimization framework provides a new solution path for the elastic-plastic large deformation problem that is unable to be resolved by using classical gradient algorithms or genetic algorithms, and simplifies the design process of energy-absorbing mechanical metamaterials.

3D-Printing Damage-Tolerant Architected Metallic Materials with Shape Recoverability via Special Deformation Design of Constituent Material.

Architected metallic materials generally suffer from a serious engineering problem of mechanical instability manifested as the emergence of localized deformation bands and collapse of strength. They usually cannot exhibit satisfactory shape recoverability due to the little recoverable strain of metallic constituent material. After yielding, the metallic constituent material usually exhibits a continuous low strain-hardening capacity, giving the local yielded regions of architecture low load resistance and easily developing into excessive deformation bands, accompanied by the collapse of strength. Here, a novel constituent material deformation design strategy has been skillfully proposed, where the low load resistance of yielded regions of the architecture can be effectively compensated by the significant self-strengthening behavior of constituent material, thus avoiding the formation of localized deformation bands and collapse of strength. To substantiate this strategy, shape-memory alloys (SMAs) are considered as suitable constituent materials for possessing both self-strengthening behavior and shape-recovery function. A 3D-printing technique was adopted to prepare various NiTi SMA architected materials with different geometric structures. It is demonstrated that all of these architected metallic materials can be stably and uniformly compressed by up to 80% without the formation of localized bands, collapse of strength, and structural failure, exhibiting ultrahigh damage tolerance. Furthermore, these SMA architected materials can display more than 98% shape recovery even after 80% deformation and excellent cycle stability during 15 cycles. This work exploits the amazing impact of constituent materials on constructing supernormal properties of architected materials and will open new avenues for developing high-performance architected metallic materials.

Designing Mechanical Metamaterials with Kirigami-Inspired, Hierarchical Constructions for Giant Positive and Negative Thermal Expansion.

Advanced mechanical metamaterials with unusual thermal expansion properties represent an area of growing interest, due to their promising potential for use in a broad range of areas. In spite of previous work on metamaterials with large or ultralow coefficient of thermal expansion (CTE), achieving a broad range of CTE values with access to large thermally induced dimensional changes in structures with high filling ratios remains a key challenge. Here, design concepts and fabrication strategies for a kirigami-inspired class of 2D hierarchical metamaterials that can effectively convert the thermal mismatch between two closely packed constituent materials into giant levels of biaxial/uniaxial thermal expansion/shrinkage are presented. At large filling ratios (>50%), these systems offer not only unprecedented negative and positive biaxial CTE (i.e., -5950 and 10 710 ppm K-1 ), but also large biaxial thermal expansion properties (e.g., > 21% for 20 K temperature increase). Theoretical modeling of thermal deformations provides a clear understanding of the microstructure-property relationships and serves as a basis for design choices for desired CTE values. An Ashby plot of the CTE versus density serves as a quantitative comparison of the hierarchical metamaterials presented here to previously reported systems, indicating the capability for substantially enlarging the accessible range of CTE.

Ionic Conductive Gels for Optically Manipulatable Microwave Stealth Structures.

Smart structures with manipulatable properties are highly demanded in many fields. However, there is a critical challenge in the pursuit of transparent windows that allow optical waves (wavelength of µm-nm) for transmitting while blocking microwave (wavelength of cm) in terms of absorbing electromagnetic energy, specifically for meeting the frequency requirement for the 5th generation (5G) mobile networks. For fundamentally establishing novel manipulatable microwave absorbing structures, here, new polymeric aqueous gels as both optically transparent materials and microwave absorbing materials are demonstrated, in which polar networks play significant roles in attenuating electromagnetic energy. By manipulating the hydrogen bonding networks, the resulting optically transparent solid-state gels are able to offer the capabilities for absorbing microwaves. Interestingly, such gels can be switched into an optically opaque state via converting the amorphous state into a polycrystal state when the temperature is decreased. Such ionic conductive gels can endow the assembled sandwich windows with effective microwave absorbing capability in the range of 15-40 GHz, covering a branch of 5G frequency bands. The results highlight a new strategy for using ionic conductive gels to design and fabricate manipulatable microwave stealth structures for various applications.

Study of Size Effect on Microstructure and Mechanical Properties of AlSi10Mg Samples Made by Selective Laser Melting.

The macroscopic mechanical performance of additive manufactured structures is essential for the design and application of multiscale microlattice structure. Performance is affected by microstructure and geometrical imperfection, which are strongly influenced by the size of the struts in selective laser melting (SLM) lattice structures. In this paper, the effect of size on microstructure, geometrical imperfection, and mechanical properties was systemically studied by conducting experimental tests. A series of AlSi10Mg rod-shaped samples with various diameters were fabricated using SLM. The uniaxial tensile test results show that with the decrease in build diameter, strength and Young's modulus of strut decreased by 30% more than the stable state. The main reasons for this degradation were investigated through microscopic observation and micro X-ray computed tomography (µ-CT). In contrast with large-sized strut, the inherent porosity (1.87%) and section geometrical deviation (3%) of ponysize strut is greater because of the effect of thermal transform and hydrogen evolution, and the grain size is 0.5 µm. The discrepancy in microstructure, geometrical imperfection, and mechanical properties induced by size effect should be considered for the design and evaluation of SLM-fabricated complex structures.