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Cellular biomaterials offer unique properties for diverse biomedical applications. However, their complex viscoelastic behavior requires careful consideration for design optimization. This study explores the effective viscoelastic response of two promising unit cell designs (tetrahedron-based and octet-truss) suitable for high porosity and strong mechanics. The asymptotic homogenization (AH) method was employed to determine effective longitudinal and shear moduli, as well as Poisson's ratio, across various relative densities. Finite element simulations (ABAQUS) validated the AH results, demonstrating good agreement (<10% discrepancies). Additionally, analytical models and compression tests on 3D-printed lattice structures supported the theoretical predictions. The study revealed a strong correlation between relative density and the effective modulus of both designs. Notably, the tetrahedron-based design exhibited superior modulus, making it favorable for high loading levels, particularly when used as a high-density configuration. Both designs demonstrated minimal time-dependent elastic modulus changes and a near-constant Poisson's ratio (0.34-0.349 for octet-truss, 0.316-0.326 for tetrahedron) across a 5-50% relative density range. While minimal, time-dependent modulus reduction needs to be considered in longer-term simulations (t>107 s). This study provides valuable insights into the viscoelastic behavior of these unit cells using the homogenization method, with potential applications in various biomedical fields.

Material-extrusion-based 3D printing with polylactic acid (PLA) has transformed the production of lightweight lattice structures with a high strength-to-weight ratio for various industries. While PLA offers advantages such as eco-friendliness, affordability, and printability, its mechanical properties degrade due to environmental factors. This study investigated the impact resistance of PLA lattice structures subjected to material degradation under room temperature, humidity, and natural light exposure. Four lattice core types (auxetic, negative-to-positive (NTP) gradient in terms of Poisson's ratio, positive-to-negative (PTN) gradient in terms of Poisson's ratio, and honeycomb) were analyzed for variations in mechanical properties due to declines in yield stress and failure strain. Mechanical testing and numerical simulations at various yield stress and failure strain levels evaluated the degradation effect, using undegraded material as a reference. The results showed that structures with a negative Poisson's ratio exhibited superior resistance to local crushing despite material weakening. Reducing the material's brittleness (failure strain) had a greater impact on impact response compared to reducing its yield stress. This study also revealed the potential of gradient cores, which exhibited a balance between strength (maintaining similar peak force to auxetic cores around 800 N) and energy absorption (up to 40% higher than auxetic cores) under moderate degradation (yield strength and failure strain at 60% and 80% of reference values). These findings suggest that gradient structures with varying Poisson's ratios employing auxetic designs are valuable choices for AM parts requiring both strength and resilience in variable environmental conditions.

The aim of the present work is to design active acoustic metamaterial consisting of an array of Helmholtz resonators and fabricating them using an additive manufacturing technique in order to assist in a reduction in noise levels in aerospace applications. To this aim, initially, a passive metamaterial consisting of an array of 64 Helmholtz resonator unit cells is designed and tested to establish the effectiveness and region of performance. The selected design variable for change is identified as the resonator cavity depth through the frequency response for each parameter of the Helmholtz resonance equation and randomized to achieve a broadband frequency range of the passive metamaterial. An active model of this design (actuated by a stepper motor) is fabricated and tested. The metamaterials are tested under two acoustic set-ups: a closed system aimed at recreating the environment of a soundproof room and an open-system aimed to recreate the condition of an active liner. For the case of passive system, the metamaterial gave sound attenuation of 18 dB (for f = 150 Hz) in open system configuration and 33 dB (f = 350 Hz) in closed system configuration. The attenuation obtained for the active model was 10-15 dB over the mean line performance for the case of closed system and 15-20 dB for the case of open system. The closed system was also tested for performance at multiple cavity depths by setting two wall depths at 10 mm and three walls at 50 mm. This test yielded an attenuation of 15 dB at 180 Hz, the frequency corresponding to 50 mm cavity depth, and 10 dB at 515 Hz, corresponding to 10 mm cavity depth.

Due to payload weight limitations and human vulnerability to harsh space conditions, it is preferable that the potential landing location for humans has an already constructed habitat preferably made from in situ materials. Therefore, the prospect of utilizing a readily available Martian material, such as regolith, in an easily programmable manufacturing method, such as 3D printing, is very lucrative. The goal of this research is to explore a mixture containing Martian regolith for the purposes of 3D printing in unfavorable conditions. A binder consisting of water and sodium silicate is used. Martian conditions are less favorable for the curing of such a mixture because of low temperature and pressure on the surface of the planet. In order to evaluate mechanical properties of the mixture, molding and 3D printing were conducted at various curing conditions and the mechanical and physical characteristics were compared. Due to the combination of low reaction speed at low temperature (2 °C) and rapid water evaporation at low pressure (0.1-0.01 bar), curing of the specimens in Martian conditions yielded unsatisfactory results. The reaction medium (water) evaporated before the curing reaction could progress enough to form a proper geopolymer. The specimens cured at high temperatures (60 °C) showed satisfactory results, with flexural strength up to 9 MPa when cured at a temperature of 60 °C and pressure of 1 bar. The specimens manufactured by 3D printing showed ultimate flexural strength that was 20% lower than that of equivalent molded specimens. Exploring potential mixture modifications and performing improved tests using the basis laid in this research can lead to an effective and realistic way of utilizing Martian regolith for unmanned 3D-printing purposes with minimal investment.

In the present study, the fatigue behavior and tensile strength of A6061-T4 aluminum alloy, joined by friction stir spot welding (FSSW), are numerically investigated. The 3D finite element model (FEM) is used to analyze the FSSW joint by means of Abaqus software. The tensile strength is determined for FSSW joints with both a probe hole and a refilled probe hole. In order to calculate the fatigue life of FSSW joints, the hysteresis loop is first determined, and then the plastic strain amplitude is calculated. Finally, by using the Coffin-Manson equation, fatigue life is predicted. The results were verified against available experimental data from other literature, and a good agreement was observed between the FEM results and experimental data. The results showed that the joint's tensile strength without a probe hole (refilled hole) is higher than the joint with a probe hole. Therefore, re-filling the probe hole is an effective method for structures jointed by FSSW subjected to a static load. The fatigue strength of the joint with a re-filled probe hole was nearly the same as the structure with a probe hole at low applied loads. Additionally, at a high applied load, the fatigue strength of joints with a refilled probe hole was slightly lower than the joint with a probe hole.

Bonded patches are widely used in several industry sectors for repairing damaged plates, cracks in metallic structures, and reinforcement of damaged structures. Composite patches have optimal properties such as high strength-to-weight ratio, easiness in being applied, and high flexibility. Due to recent rapid growth in the aerospace industry, analyses of adhesively bonded patches applicable to repairing cracked structures have become of great significance. In the present study, the fatigue behavior of the aluminum alloy, repaired by a double-sided glass/epoxy composite patch, is studied numerically. More specifically, the effect of applying a double-sided composite patch on the fatigue life improvement of a damaged aluminum 6061-T6 is analyzed. 3D finite element numerical modeling is performed to analyze the fatigue performance of both repaired and unrepaired aluminum plates using the Abaqus package. To determine the fatigue life of the aluminum 6061-T6 plate, first, the hysteresis loop is determined, and afterward, the plastic strain amplitude is calculated. Finally, by using the Coffin-Manson equation, fatigue life is predicted and validated against the available experimental data from the literature. Results reveal that composite patches increase the fatigue life of cracked structures significantly, ranging from 55% to 100% for different applied stresses.

Mechanical metamaterials are man-made rationally-designed structures that present unprecedented mechanical properties not found in nature. One of the most well-known mechanical metamaterials is auxetics, which demonstrates negative Poisson's ratio (NPR) behavior that is very beneficial in several industrial applications. In this study, a specific type of auxetic metamaterial structure namely idealized 3D re-entrant structure is studied analytically, numerically, and experimentally. The noted structure is constructed of three types of struts-one loaded purely axially and two loaded simultaneously flexurally and axially, which are inclined and are spatially defined by angles θ and φ. Analytical relationships for elastic modulus, yield stress, and Poisson's ratio of the 3D re-entrant unit cell are derived based on two well-known beam theories namely Euler-Bernoulli and Timoshenko. Moreover, two finite element approaches one based on beam elements and one based on volumetric elements are implemented. Furthermore, several specimens are additively manufactured (3D printed) and tested under compression. The analytical results had good agreement with the experimental results on the one hand and the volumetric finite element model results on the other hand. Moreover, the effect of various geometrical parameters on the mechanical properties of the structure was studied, and the results demonstrated that angle θ (related to tension-dominated struts) has the highest influence on the sign of Poisson's ratio and its extent, while angle φ (related to compression-dominated struts) has the lowest influence on the Poisson's ratio. Nevertheless, the compression-dominated struts (defined by angle φ) provide strength and stiffness for the structure. The results also demonstrated that the structure could have zero Poisson's ratio for a specific range of θ and φ angles. Finally, a lightened 3D re-entrant structure is introduced, and its results are compared to those of the idealized 3D re-entrant structure.

Stress shielding and micromotions are the most significant problems occurring at the bone-implants interface due to a mismatch of their mechanical properties. Mechanical 3D metamaterials, with their exceptional behaviour and characteristics, can provide an opportunity to solve the mismatch of mechanical properties between the bone and implant. In this study, a new porous femoral hip meta-implant with graded Poisson's ratio distribution was introduced and its results were compared to three other femoral hip implants (one solid implant, and two porous meta-implants, one with positive and the other with a negative distribution of Poisson's ratio) in terms of stress and micromotion distributions. For this aim, first, a well-known auxetic 3D re-entrant structure was studied analytically, and precise closed-form analytical relationships for its elastic modulus and Poisson's ratio were derived. The results of the analytical solution for mechanical properties of the 3D re-entrant structure presented great improvements in comparison to previous analytical studies on the structure. Moreover, the implementation of the re-entrant structure in the hip implant provided very smooth results for stress and strain distributions in the lattice meta-implants and could solve the stress shielding problem which occurred in the solid implant. The lattice meta-implant based on the graded unit cell distribution presented smoother stress-strain distribution in comparison with the other lattice meta-implants. Moreover, the graded lattice meta-implant gave minimum areas of local stress and local strain concentration at the contact region of the implants with the internal bone surfaces. Among all the cases, the graded meta-implant also gave micromotion levels which are the closest to values reported to be desirable for bone growth (40 µm).

Metamaterials are periodic structures which offer physical properties not found in nature. Particularly, acoustic metamaterials can manipulate sound and elastic waves both spatially and spectrally in unpreceded ways. Acoustic metamaterials can generate arbitrary acoustic bandgaps by scattering sound waves, which is a superior property for insulation properties. In this study, one dimension of the resonators (depth of cavity) was altered by means of a pneumatic actuation system. To this end, metamaterial slabs were additively manufactured and connected to a proportional pressure control unit. The noise reduction performance of active acoustic metamaterials in closed- and open-space configurations was measured in different control conditions. The pneumatic actuation system was used to vary the pressure behind pistons inside each cell of the metamaterial, and as a result to vary the cavity depth of each unit cell. Two pressures were considered, P = 0.05 bar, which led to higher depth of the cavities, and P = 0.15 bar, which resulted in lower depth of cavities. The results showed that by changing the pressure from P = 0.05 (high cavity depth) to P = 0.15 (low cavity depth), the acoustic bandgap can be shifted from a frequency band of 150-350 Hz to a frequency band of 300-600 Hz. The pneumatically-actuated acoustical metamaterial gave a peak attenuation of 20 dB (at 500 Hz) in the closed system and 15 dB (at 500 Hz) in the open system. A step forward would be to tune different unit cells of the metamaterial with different pressure levels (and therefore different cavity depths) in order to target a broader range of frequencies.

Studies on porous trailing edges, manufactured with open-cell Ni-Cr-Al foams with sub-millimeter pore sizes, have shown encouraging results for the mitigation of turbulent boundary-layer trailing-edge noise. However, the achieved noise mitigation is typically dependent upon the pore geometry, which is fixed after manufacturing. In this study, a step to control the aeroacoustics effect of such porous trailing edges is taken, by applying a polymeric coating onto the internal foam structure. Using this method, the internal topology of the foam is maintained, but its permeability is significantly affected. This study opens a new possibility of aeroacoustic control, since the polymeric coatings are temperature responsive, and their thickness can be controlled inside the foam. Porous metallic foams with pore sizes of 580, 800, and 1200 μm are (internally) spray-coated with an elastomeric coating. The uncoated and coated foams are characterized in terms of reduced porosity, average coating thickness and air-flow resistance. Subsequently, the coated and uncoated foams are employed to construct tapered inserts installed at the trailing edge of an NACA 0018 airfoil. The noise mitigation performances of the coated metal foams are compared to those of uncoated metal foams with either similar pore size or permeability value, and both are compared to the solid trailing edge reference case. Results show that that the permeability of the foam can be easily altered by the application of an internal coating on the metallic foams. The noise reduction characteristics of the coated foams are similar to equivalent ones with metallic materials, provided that the coating material is rigid enough not to plastically deform under flow conditions.

Honeycombs resemble the structure of a number of natural and biological materials such as cancellous bone, wood, and cork. Thick honeycomb could be also used for energy absorption applications. Moreover, studying the mechanical behavior of honeycombs under in-plane loading could help understanding the mechanical behavior of more complex 3D tessellated structures such as porous biomaterials. In this paper, we study the mechanical behavior of thick honeycombs made using additive manufacturing techniques that allow for fabrication of honeycombs with arbitrary and precisely controlled thickness. Thick honeycombs with different wall thicknesses were produced from polylactic acid (PLA) using fused deposition modelling, i.e., an additive manufacturing technique. The samples were mechanically tested in-plane under compression to determine their mechanical properties. We also obtained exact analytical solutions for the stiffness matrix of thick hexagonal honeycombs using both Euler-Bernoulli and Timoshenko beam theories. The stiffness matrix was then used to derive analytical relationships that describe the elastic modulus, yield stress, and Poisson's ratio of thick honeycombs. Finite element models were also built for computational analysis of the mechanical behavior of thick honeycombs under compression. The mechanical properties obtained using our analytical relationships were compared with experimental observations and computational results as well as with analytical solutions available in the literature. It was found that the analytical solutions presented here are in good agreement with experimental and computational results even for very thick honeycombs, whereas the analytical solutions available in the literature show a large deviation from experimental observation, computational results, and our analytical solutions.