Adjustable Ultra-Light Mechanical Negative Poisson's Ratio Metamaterials with Multi-Level Dynamic Crushing Effects.

Mechanical metamaterials with multi-level dynamic crushing effects (MM-MLs) are designed in this study through coordinate transformation and mirror arrays. The mechanical effects of the diameter and length ratio of the struts and connecting rods, the Euler angles, and the cell numbers on the mechanical properties are investigated separately. MM-ML can exhibit significant two-level platform stress, and the local cells in the first platform stress stage undergo rotational motion, while the second platform stress stage mainly involves collapse compression and bending. Although increasing the length of the connecting rods can increase the range of Poisson's ratio, it will reduce the level of platform stress and energy absorption. Increasing the Euler angle will reduce the strain interval of the first platform stress and can improve the energy absorption capacity. In addition, increasing the cell number while maintaining a constant relative density can effectively enhance energy absorption. MM-ML has significant parameter controllability, can achieve different platform stress regions, different ranges of Poisson's ratios, and energy absorption requirements according to the application scenario, and can demonstrate functional diversity compared to existing research. The design scheme can provide ideas for adaptive crushing protection requirements.

Roles of collagen cross-links and osteon collagen/lamellar morphotypes in equine third metacarpals in tension and compression tests.

Many bones experience bending, placing one side in net compression and the other in net tension. Because bone mechanical properties are relatively reduced in tension compared with compression, adaptations are needed to reduce fracture risk. Several toughening mechanisms exist in bone, yet little is known of the influences of secondary osteon collagen/lamellar 'morphotypes' and potential interplay with intermolecular collagen cross-links (CCLs) in prevalent/predominant tension- and compression-loaded regions. Paired third metacarpals (MC3s) from 10 adult horses were prepared for mechanical testing. From one MC3/pair, 5 mm cubes were tested in compression at several mid-shaft locations. From contralateral bones, dumbbell-shaped specimens were tested in tension. Hence, habitual/natural tension- and compression-loaded regions were tested in both modes. Data included: elastic modulus, yield and ultimate strength, and energy absorption (toughness). Fragments of tested specimens were examined for predominant collagen fiber orientation (CFO; representing osteonal and non-osteonal bone), osteon morphotype score (MTS, representing osteonal CFO), mineralization, porosity and other histological characteristics. As a consequence of insufficient material from tension-tested specimens, CCLs were only examined in compression-tested specimens (HP, hydroxylysylpyridinoline; LP, lysylpyridinoline; PE, pentosidine). Among CCLs, only LP and HP/LP correlated significantly with mechanical parameters: LP with energy absorption, HP/LP with elastic modulus (both r=0.4). HP/LP showed a trend with energy absorption (r=-0.3, P=0.08). HP/LP more strongly correlated with osteon density and mineralization than CFO or MTS. Predominant CFO more strongly correlated with energy absorption than MTS in both testing modes. In general, CFO was found to be relatively prominent in affecting regional toughness in these equine MC3s in compression and tension.

Wire Arc Additive Manufacturing of Aluminum Foams Using TiH2-Laced Welding Wires.

Composite materials made from aluminum foam are increasingly used in aerospace and automotive industries due to their low density, high energy absorption capacity, and corrosion resistance. Additive manufacturing processes offer several advantages over conventional manufacturing methods, such as the ability to produce significantly more geometrically complex components without the need for expensive tooling. Direct Energy Deposition processes like Wire Arc Additive Manufacturing (WAAM) enable the additive production of near-net-shape components at high build rates. This paper presents a technology for producing aluminum foam structures using WAAM. This paper's focus is on the development of welding wires that are mixed with a foaming agent (TiH2) and produce a foamed weld metal as well as their processing using MIG welding technology.

Energy Absorption and Failure Modes of Different Composite Open-Section Crush Elements under Axial Crushing Loading.

In order to study the energy absorption characteristics of the open-section thin-walled composite structures with different cross-sections, axial compression tests were carried out at loading speeds of 0.01 m/s, 0.1 m/s, and 1 m/s. Finite element models were built to predict the crushing response and energy absorption behaviors of these open-section structures. The effects of the cross-section's shape, cross-section aspect ratio, trigger mechanism, and loading speed on the energy absorption characteristics of the composite structures were analyzed. The results show that the average crushing loads of the hat-shaped and Ω-shaped open-section structures are 14.1% and 14.6% higher than those of C-shaped open-section structures, and the specific energy absorption (SEA) values are 14.3% and 14.8% higher than that of C-shaped open-section structures, respectively. For the C-shaped open-section structures, a 45° chamfer trigger is more effective in reducing the initial peak load, while a 15° steeple trigger is more appropriate for the hat-shaped open-section structures. The average crushing loads and SEA of C-shaped, hat-shaped, and Ω-shaped open-section structures are reduced when the loading speed is increased from 0.01 m/s to 1 m/s. The increase in loading speed leads to the splashing of debris and thus reduces the loading area and material utilization of open-section structures, leading to a decrease in energy absorption efficiency.

Research Progress on Helmet Liner Materials and Structural Applications.

As an important part of head protection equipment, research on the material and structural application of helmet liners has always been one of the hotspots in the field of helmets. This paper first discusses common helmet liner materials, including traditional polystyrene, polyethylene, polypropylene, etc., as well as newly emerging anisotropic materials, polymer nanocomposites, etc. Secondly, the design concept of the helmet liner structure is discussed, including the use of a multi-layer structure, the addition of geometric irregular bubbles to enhance the energy absorption effect, and the introduction of new manufacturing processes, such as additive manufacturing technology, to realize the preparation of complex structures. Then, the application of biomimetic structures to helmet liner design is analyzed, such as the design of helmet liner structures with more energy absorption properties based on biological tissue structures. On this basis, we propose extending the concept of bionic structural design to the fusion of plant stalks and animal skeletal structures, and combining additive manufacturing technology to significantly reduce energy loss during elastic yield energy absorption, thus developing a reusable helmet that provides a research direction for future helmet liner materials and structural applications.

On the Crush Behavior and Energy Absorption of Sustainable Beverage Cans and Their Polyurethane Foam-Filled Structures: An Experimental Study.

In the pursuit of global energy conservation and emissions reductions, utilizing beverage cans as energy-absorbing components offers potential for a sustainable economy. This study examines the impact of foam filling on the crushing behaviors and energy absorption of various types of beverage cans. Quasi-static compression tests were conducted on five geometrically sized cans filled with three densities of polyurethane foam to study their deformation modes and calculate crashworthiness parameters within the effective stroke. Results show that empty beverage cans have lower energy absorption capacities, and deformation modes become less consistent as can size increases. Higher foam density leads to increased total energy absorption, a slight reduction in the effective compression stroke, and a tendency for specific energy absorption to initially increase and then decrease. Regarding crush behavior, smaller cans transition from a diamond mode to a concertina mode, while larger cans exhibit a columnar bending mode. Next, the coupling effect of energy absorption between foam and cans was analyzed so as to reveal the design method of energy-absorbing components. The specific energy absorption of smaller cans filled with polyurethane foam is superior to that of similar empty cans. These findings provide valuable insights for selecting next-generation sustainable energy absorption structures.

Characterization of Magnetorheological Impact Foams in Compression.

This study focuses on the development and compressive characteristics of magnetorheological elastomeric foam (MREF) as an adaptive cushioning material designed to protect payloads from a broader spectrum of impact loads. The MREF exhibits softness and flexibility under light compressive loads and low strains, yet it becomes rigid in response to higher impact loads and elevated strains. The synthesis of MREF involved suspending micron-sized carbonyl Fe particles in an uncured silicone elastomeric foam. A catalyzed addition crosslinking reaction, facilitated by platinum compounds, was employed to create the rapidly setting silicone foam at room temperature, simplifying the synthesis process. Isotropic MREF samples with varying Fe particle volume fractions (0%, 2.5%, 5%, 7.5%, and 10%) were prepared to assess the effect of particle concentrations. Quasi-static and dynamic compressive stress tests on the MREF samples placed between two multipole flexible strip magnets were conducted using an Instron servo-hydraulic test machine. The tests provided measurements of magnetic field-sensitive compressive properties, including compression stress, energy absorption capability, complex modulus, and equivalent viscous damping. Furthermore, the experimental investigation also explored the influence of magnet placement directions (0° and 90°) on the compressive properties of the MREFs.

Hybridizing Shear-Stiffening Gel and Chemically-Strengthened Ultrathin Glass Sheets for Flexible Impact-Resistant Armor.

Traditional anti-impact armors and shields are normally made of stiff and hard materials and therefore deficient in flexibility. This greatly limits their applications in protecting objects with complex geometries or significant deformability. Flexible armors can be developed with the application of hard platelets and soft materials, but the lower rigidity of the flexible armors renders them incapable of providing sufficient resistance against impact attacks. To address the inherent conflict between flexibility and impact resistance in traditional armors, here, a composite is developed by hybridizing a shear-stiffening gel as the matrix and chemically-strengthened ultrathin glass sheets (CSGS) as the reinforcement. The resulting laminate, termed PCCL, exhibits both high flexibility and high impact resistance. Specifically, at low strain rates, the high ductility of the gel combined with the high flexural strength of the CSGS enables the PCCL to undergo considerable deformation; at high strain rates, on the other hand, the shear stiffening behavior of the gel matrix endows the PCCL with excellent impact resistance manifested by its high performance in energy absorption and high rigidity. With the combination of high flexibility and high impact resistance, the PCCL is demonstrated to be an ideal armor for protecting curved vulnerable objects from impact attacks.

Bionic design of thin-walled bilinear tubes with excellent crashworthiness inspired by glass sponge structures.

In order to enhance energy absorption, this study draws inspiration from the diagonal bilinear robust square lattice structure found in deep-sea glass sponges, proposing a design for thin-walled structures with superior folding capabilities and high strength-to-weight ratio. Firstly, the crashworthiness of bionic glass sponge tube (BGSTO) is compared with that of equal-wall-thickness equal-mass four-X tube through both experiments and simulations, and it is obtained that the specific energy absorption of BGSTO is increased by 78.64%. And the crashworthiness of BGSTO is also most significant compared to that of multicellular tubes with the similar number of crystalline cells. Additionally, we found that the double-line spacing of the glass sponge can be freely adjusted without changing the material amount. Therefore, based on BGSTO, we designed two other double-line structures, BGSTA and BGSTB. Then with equal wall thickness and mass as a prerequisite, this study proceeds to design and compare the energy absorption properties of three bilinear thin-walled tubes in both axial and lateral cases. The deformation modes and crashworthiness of the three types of tubes with variable bilinear spacing (ßO/A/B) are comparatively analysed. The improved complex proportional assessment (COPRAS) synthesis decision is used to obtain that BGSTO exhibits superior crashworthiness over the remaining two kinds of tubes. Finally, a surrogate model is established to perform multi-objective optimization on the optimal bilinear configuration BGSTO selected by the COPRAS method.

Analysis of deformation and failure mechanism of sandwich beams with lattice core under three-point bending load.

This paper investigates sandwich beams with lattice cores under quasi-static bending, owing to their lightweight nature and high energy absorption capabilities. Utilizing analytical methods governing beams, an investigation into their failure mechanisms is conducted, incorporating experimental and numerical results. The influence of thickness and core cell sizes on energy absorption are examined. The analysis delves into the elastic and plastic behavior of the beam, which is refined and validated against the numerical and experimental tests and failure modes of sandwich panel beams. The alignment of analytical predictions with both experimental and numerical results in terms of mean forces, and energy absorptions was remarkably precise. Moreover, evidence has been presented that the face yield and core shear failure regions are significantly impacted by variances in core dimensions. Additionally, the thickness of core cell strands was found to be pivotal in influencing the compressive and shear strengths of sandwich panel beams.

Crushing Response and Optimization of a Modified 3D Re-Entrant Honeycomb.

A modified 3D re-entrant honeycomb is designed and fabricated utilizing Laser Cladding Deposition (LCD) technology, the mechanical properties of which are systematically investigated by experimental and finite element (FE) methods. Firstly, the influences of honeycomb angle on localized deformation and the response of force are studied by an experiment. Experimental results reveal that the honeycomb angles have a significant effect on deformation and force. Secondly, a series of numerical studies are conducted to analyze stress characteristics and energy absorption under different angles (α) and velocities (v). It is evident that two variables play an important role in stress and energy. Thirdly, response surface methodology (RSM) and the Non-Dominated Sorting Genetic Algorithm II (NSGA-II) are implemented with high precision to solve multi-objective optimization. Finally, the final compromise solution is determined based on the fitness function, with an angle of 49.23° and an impact velocity of 16.40 m/s. Through simulation verification, the errors of energy absorption (EA) and peak crush stress (PCS) are 9.26% and 0.4%, respectively. The findings of this study offer valuable design guidance for selecting the optimal design parameters under the same mass conditions to effectively enhance the performance of the honeycomb.

Study on Dynamic Mechanical Properties of Sandwich Beam with Stepwise Gradient Polymethacrylimide (PMI) Foam Core under Low-Velocity Impact.

Different PMI foam materials of 52, 110, and 200 kg/m3 were used to design stepwise gradient cores to improve the impact resistance of the sandwich beam. The stepwise gradient core consists of three layers arranged in positive gradient, negative gradient, and sandwich-core (e.g., 200/52/200). These sandwich beams were subjected to the impact of a steel projectile under impact momentum of 10 to 20 kg·m/s, corresponding to impact energy in the range of 12.5 to 50 J. During the test, the impact force was recorded by an accelerometer, and the different failure modes were also obtained. Subsequently, the influence of the layer arrangement on the energy absorption and load transfer mechanism between the different layers was analyzed. The results showed that the top layer with a large density can improve the impact force, but the middle/bottom layer with a low density promoted specific energy absorption. Thus, based on these two points, the negative gradient core (200/110/52) had an excellent specific energy absorption because it can transfer and expand the area to bear the load layer by layer, which improved the energy absorption in each layer. Combined with the failure modes, the load transfer and deformation mechanisms between the layers were also discussed. The present work provided a valuable method to design an efficient lightweight sandwich structure in the protection field.

A Bioinspired Design of Protective Al2O3/Polyurethane Hierarchical Composite Film Through Layer-By-Layer Deposition.

Structural materials such as ceramics, metals, and carbon fiber-reinforced plastics (CFRP) are frequently threatened by large compressive and impact forces. Energy absorption layers, i.e., polyurethane and silicone foams with excellent damping properties, are applied on the surfaces of different substrates to absorb energy. However, the amount of energy dissipation and penetration resistance are limited in commercial polyurethane foams. Herein, a distinctive nacre-like architecture design strategy is proposed by integrating hard porous ceramic frameworks and flexible polyurethane buffers to improve energy absorption and impact resistance. Experimental investigations reveal the bioinspired designs exhibit optimized hardness, strength, and modulus compared to that of polyurethane. Due to the multiscale energy dissipation mechanisms, the resulting normalized absorbed energy (≈8.557 MJ m-3) is ≈20 times higher than polyurethane foams under 50% quasi-static compression. The bioinspired composites provide superior protection for structural materials (CFRP, glass, and steel), surpassing polyurethane films under impact loadings. It is shown CFRP coated with the designed materials can withstand more than ten impact loadings (in energy of 10 J) without obvious damage, which otherwise delaminates after a single impact. This biomimetic design strategy holds the potential to offer valuable insights for the development of lightweight, energy-absorbent, and impact-resistant materials.

Effect of Geometrical Parameters on the Mechanical Performance of Bamboo-Inspired Gradient Hollow-Strut Octet Lattice Structure Fabricated by Additive Manufacturing.

Hollow-strut metal lattice structures are currently attracting extensive attention due to their excellent mechanical performance. Inspired by the node structure of bamboo, this study aimed to investigate the mechanical performance of the gradient hollow-strut octet lattice structure fabricated by laser powder bed fusion (LPBF). The effect of geometrical parameters on the yield strength, Young's modulus and energy absorption of the designed octet unit cells were studied and optimized by FEA analysis. The hollow-strut geometrical parameters that deliver the best mechanical property combinations were identified, and the corresponding unit cells were then redesigned into the 3 × 3 × 3 type lattice structures for experimental evaluations. Compression tests confirmed that the designed gradient hollow-strut octet lattice structures demonstrated superior mechanical properties and deformation stability than their solid-strut lattice structure counterparts. The underlying deformation mechanism analysis revealed that the remarkably enhanced bending strength of the gradient hollow-strut lattice structure made significant contributions to its mechanical performance improvement. This study is envisaged to shed light on future hollow-strut metal lattice structure design for lightweight applications, with the final aim of enhancing the component's mechanical properties and/or lowering its density as compared with the solid-strut lattice structures.

Design, Manufacturing, and Analysis of Periodic Three-Dimensional Cellular Materials for Energy Absorption Applications: A Critical Review.

Cellular materials offer industries the ability to close gaps in the material selection design space with properties not otherwise achievable by bulk, monolithic counterparts. Their superior specific strength, stiffness, and energy absorption, as well as their multi-functionality, makes them desirable for a wide range of applications. The objective of this paper is to compile and present a review of the open literature focusing on the energy absorption of periodic three-dimensional cellular materials. The review begins with the methodical cataloging of qualitative and quantitative elements from 100 papers in the available literature and then provides readers with a thorough overview of the state of this research field, discussing areas such as parent material(s), manufacturing methods, cell topologies, cross-section shapes for truss topologies, analysis methods, loading types, and test strain rates. Based on these collected data, areas of great and limited research are identified and future avenues of interest are suggested for the continued maturation and growth of this field, such as the development of a consistent naming and classification system for topologies; the creation of test standards considering additive manufacturing processes; further investigation of non-uniform and non-cylindrical struts on the performance of truss lattices; and further investigation into the performance of lattice materials under the impact of non-flat surfaces and projectiles. Finally, the numerical energy absorption (by mass and by volume) data of 76 papers are presented across multiple property selection charts, highlighting various materials, manufacturing methods, and topology groups. While there are noticeable differences at certain densities, the graphs show that the categorical differences within those groups have large overlap in terms of energy absorption performance and can be referenced to identify areas for further investigation and to help in the preliminary design process by researchers and industry professionals alike.

Crashworthiness Study of Functional Gradient Lattice-Reinforced Thin-Walled Tubes under Impact Loading.

Creating lightweight and impact-resistant box structures has been an enduring pursuit among researchers. A new energy-absorbing structure consisting of a bionic gradient lattice-enhanced thin-walled tube is presented in this article. The gradient lattice and thin-walled tube were prepared using selective laser melting (SLM) and wire-cutting techniques, respectively. To analyze the effects of gradient pattern, mass ratio, diameter range and impact speed on structural crashworthiness, low-speed impact at 4 m/s and finite element simulation experiments were conducted. The study demonstrates that the design of inward radial gradient lattice-reinforced thin-walled tubes can effectively enhance structure's energy-absorption efficiency and provide a more stable mode of deformation. It also shows a 17.44% specific energy-absorption advantage over the uniformly lattice-reinforced thin-walled tubes, with no significant overall gain in peak crushing force. A complex scale evaluation method was used to determine the optimum structure and the structure type with the best crashworthiness was found to be a gradient lattice-filled tube with a thickness of 0.9 mm and a slope index of 10. The gradient lattice-reinforced thin-walled tube suggested in this investigation offers guidance for designing a more efficient thin-walled energy-absorption structure.

Design of Customized Mouthguards with Superior Protection Using Digital-Based Technologies and Impact Tests.

BACKGROUND: In contact sports, an impact on the jaw can generate destructive stress on the tooth-bone system. Mouthguards can be beneficial in reducing the injury risk by changing the dynamics of the trauma. The material properties of mouthguards and their geometrical/structural attributes influence their protective performance. Custom-made mouthguards are the gold standard, and different configurations have been proposed to improve their protection and comfort. However, the effects of different design variables on the performance of customized mouthguards are not well understood. RESULTS: Herein, we developed a reliable finite element model to analyze contributing factors to the design of custom-made mouthguards. Accordingly, we evaluated the isolated and combined effect of layers' stiffness, thickness, and space inclusion on the protective capability of customized mouthguards. Our simulations revealed that a harder frontal region could distribute load and absorb impact energy through bending if optimally combined with a space inclusion. Moreover, a softer layer could enlarge the time of impact and absorb its energy by compression. We also showed that mouthguards present similar protection with either permanently bonded or mechanically interlocked components. We 3D-printed different mouthguards with commercial resins and performed impact tests to experimentally validate our simulation findings. The impact tests on the fabricated mouthguards used in this work revealed that significantly higher dental protection could be achieved with 3D-printed configurations than conventionally fabricated customized mouthguards. In particular, the strain on the impacted incisor was attenuated around 50% more with a 3D-printed mouthguard incorporating a hard insert and space in the frontal region than a conventional Playsafe® Heavypro mouthguard. CONCLUSIONS: The protective performance of a mouthguard could be maximized by optimizing its structural and material properties to reduce the risk of sport-related dental injuries. Combining finite element simulations, additive manufacturing, and impact tests provides an efficient workflow for developing functional mouthguards with higher protectiveness and athlete comfort. We envision the future with 3d-printed custom-mouthguards presenting distinct attributes in different regions that are personalized by the user based on the sport and associated harshness of the impact incidences.

Crashworthiness of 3D Lattice Topologies under Dynamic Loading: A Comprehensive Study.

Periodic truss-based lattice materials, a particular subset of cellular solids that generally have superior specific properties as compared to monolithic materials, offer regularity and predictability that irregular foams do not. Significant advancements in alternative technologies-such as additive manufacturing-have allowed for the fabrication of these uniquely complex materials, thus boosting their research and development within industries and scientific communities. However, there have been limitations in the comparison of results for these materials between different studies reported in the literature due to differences in analysis approaches, parent materials, and boundary and initial conditions considered. Further hindering the comparison ability was that the literature generally only focused on one or a select few topologies. With a particular focus on the crashworthiness of lattice topologies, this paper presents a comprehensive study of the impact performance of 24 topologies under dynamic impact loading. Using steel alloy parent material (manufactured using Selective Laser Melting), a numerical study of the impact performance was conducted with 16 different impact energy-speed pairs. It was possible to observe the overarching trends in crashworthiness parameters, including plateau stress, densification strain, impact efficiency, and absorbed energy for a wide range of 3D lattice topologies at three relative densities. While there was no observed distinct division between the results of bending and stretching topologies, the presence of struts aligned in the impact direction did have a significant effect on the energy absorption efficiency of the lattice; topologies with struts aligned in that direction had lower efficiencies as compared to topologies without.

Investigating the Impact Behavior of Carbon Fiber/Polymethacrylimide (PMI) Foam Sandwich Composites for Personal Protective Equipment.

To improve the shock resistance of personal protective equipment and reduce casualties due to shock wave accidents, this study prepared four types of carbon fiber/polymethacrylimide (PMI) foam sandwich panels with different face/back layer thicknesses and core layer densities and subjected them to quasi-static compression, low-speed impact, high-speed impact, and non-destructive tests. The mechanical properties and energy absorption capacities of the impact-resistant panels, featuring ceramic/ultra-high molecular-weight polyethylene (UHMWPE) and carbon fiber/PMI foam structures, were evaluated and compared, and the feasibility of using the latter as a raw material for personal impact-resistant equipment was also evaluated. For the PMI sandwich panel with a constant total thickness, increasing the core layer density and face/back layer thickness enhanced the energy absorption capacity, and increased the peak stress of the face layer. Under a constant strain, the energy absorption value of all specimens increased with increasing impact speed. When a 10 kg hammer impacted the specimen surface at a speed of 1.5 m/s, the foam sandwich panels retained better integrity than the ceramic/UHMWPE panel. The results showed that the carbon fiber/PMI foam sandwich panels were suitable for applications that require the flexible movement of the wearer under shock waves, and provide an experimental basis for designing impact-resistant equipment with low weight, high strength, and high energy absorption capacities.

A Comparative Study on Impact Resistance of Cylindrical Structures with Cushioning Energy Absorbing Rings under Double Impact Loading.

In this paper, the impact resistance of a cylindrical structure with a buffer ring and an energy-absorbing ring under double impact loads is studied. Based on ABAQUS 2023 finite element software, a simulation model of a buffer ring structure with three different sibs was established, and the specimens were subjected to double impact loading. The results show that the impact resistance of the structure decreases with the increase in curvature radius. The increase in the thickness of the panel can effectively reduce the deformation difference between the center point of the panel and the maximum displacement point. The buffer ring composed of cell structure with negative Poisson's ratio effect has better shock resistance under explosion load, while the buffer ring with hexagonal cellular structure has excellent kinetic energy shock resistance.