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The bonding strength, and microstructures of Cu and Al couples using metallic powders as interlayer during transient liquid phase bonding (TLP bonding) were investigated. The interfacial morphologies and microstructures were studied by scanning electron microscopy equipped with energy dispersive X-ray spectroscopy, and X-ray diffraction. First, to explore the optimum bonding time and temperature, nine samples were bonded without interlayers in a vacuum condition. Mechanical test results indicated that bonding at 560°C in 20 min returns the highest bond strength (84% of Al). This bonding condition was used to join ten samples with powder interlayers. Powders were prepared by mixing different combinations of Cu, Al (+Fe nanoparticles) and Zn. In the bonding zone, different Cu9Al4, CuAl, and CuAl2 intermetallic co-precipitate. The strongest bonding is formed in the sample with the 70Al (+Fe)-30Cu powder interlayer. Powder interlayers present thinner and more uniform intermetallic layers at the joint interface.

Summary Animals' teeth have evolved to provide food procurement, mastication, and protection. These functions, directly linked to survival of many living animal species, require superior hardness and abrasion resistance in the animal's dentition system. Such resistance typically emerges from damage tolerance and sharpness preservation during the organism’s life span. An example is the sea urchin tooth, which through gradients in mechanical properties together with exploitation of microstructural features achieves such functionality. Using contact mechanics, dimensional analysis, and a novel in situ scanning electron microscopy experimental methodology, conditions for tooth deformation and wear, via a self-sharpening mechanism consisting in plate chipping, were imaged and quantified. Nonlinear finite-element modeling of the self-sharpening mechanism provided insight into the synergy between constituent material properties and tooth microstructural elements. The findings reported here should inspire the design of novel tools used in machining operations, e.g., cutting and grinding, as well as in mining and tunnel boring.

A number of experimental techniques have been used to characterize the mechanical properties and wear of biomaterials, from nanoindentation to scratch to atomic force microscopy testing. While all these experiments provide valuable information on the mechanics and functionality of biomaterials (e.g., animals’ teeth), they lack the ability to combine the measurement of force and sliding velocities with high resolution imaging of the processes taking place at the biomaterial-substrate interface. Here we present an experiment for the in situ scanning electron microscopy characterization of the mechanics of friction and wear of biomaterials with simultaneous control of mechanical and kinematic variables. To illustrate the experimental methodology, we report the wear of the sea urchin tooth, which exhibits a unique combination of architecture and material properties tailored to withstand abrasion loads in different directions. By quantifying contact conditions and changes in the tooth tip geometry, we show that the developed methodology provides a versatile and promising tool to investigate wear mechanisms in a variety of animal teeth accounting for microscale effects.

Bighorn sheep ( Ovis canadensis ) rams hurl themselves at each other at speeds of ∼9 m/s (20 mph) to fight for dominance and mating rights. This necessitates impact resistance and energy absorption mechanisms, which stem from material-structure components in horns. In this study, the material hierarchical structure as well as correlations between the structure and mechanical properties are investigated. The major microstructural elements of horns are found as tubules and cell lamellae, which are oriented with (∼30⁰) angle with respect to each other. The cell lamellae contain keratin cells, in the shape of pancakes, possessing an average thickness of ∼2 µm and diameter of ∼20–30 µm. The morphology of keratin cells reveals the presence of keratin fibers and intermediate filaments with diameter of ∼200 nm and ∼12 nm, respectively, parallel to the cell surface. Quasi-static and high strain rate impact experiments, in different loading directions and hydration states, revealed a strong strain rate dependency for both dried and hydrated conditions. A strong anisotropy behavior was observed under impact for the dried state. The results show that the radial direction is the most preferable impact orientation because of its superior energy absorption. Detailed failure mechanisms under the aforementioned conditions are examined by bar impact recovery experiments. Shear banding, buckling of cell lamellae, and delamination in longitudinal and transverse direction were identified as the cause for strain softening under high strain rate impact. While collapse of tubules occurs in both quasi-static and impact tests, in radial and transverse directions, the former leads to more energy absorption and impact resistance. Statement of Significance Bighorn sheep ( Ovis canadensis ) horns show remarkable impact resistance and energy absorption when undergoing high speed impact during the intraspecific fights. The present work illustrates the hierarchical structure of bighorn sheep horn at different length scales and investigates the energy dissipation mechanisms under different strain rates, loading orientations and hydration states. These results demonstrate how horn dissipates large amounts of energy, thus provide a new path to fabricate energy absorbent and crashworthiness engineering materials.

Naturally occurring biological materials with stiff fibers embedded in a ductile matrix are commonly known to achieve excellent balance between stiffness, strength and ductility. In particular, biological composite materials with helicoidal architecture have been shown to exhibit enhanced damage tolerance and increased impact energy absorption. However, the role of fiber reorientation inside the flexible matrix of helicoid composites on their mechanical behaviors have not yet been extensively investigated. In the present work, we introduce a Discontinuous Fiber Helicoid (DFH) composite inspired by both the helicoid microstructure in the cuticle of mantis shrimp and the nacreous architecture of the red abalone shell. We employ 3D printed specimens, analytical models and finite element models to analyze and quantify in-plane fiber reorientation in helicoid architectures with different geometrical features. We also introduce additional architectures, i.e., single unidirectional lamina and mono-balanced architectures, for comparison purposes. Compared with associated mono-balanced architectures, helicoid architectures exhibit less fiber reorientation values and lower values of strain stiffening. The explanation for this difference is addressed in terms of the measured in-plane deformation, due to uniaxial tensile of the laminae, correlated to lamina misorientation with respect to the loading direction and lay-up sequence.

Incorporation of the first gradient of strain, in addition to the strain itself, into the strain energy density of an elastic solid leads to Mindlin’s first strain gradient theory, which is useful for examination of size effect as well as other mechanical phenomena at the nano-scale. For isotropic elastic solids, the first strain gradient theory, in addition to the two independent Lame constants, gives rise to five new material constants which in turn reduce to two material parameters, l 1 and l 2 with dimension of length. The evaluation of these parameters, however, has posed serious challenges, both experimentally and theoretically. In this work ab initio method is used to compute the characteristic lengths for several fcc and bcc metal crystals. It will be seen that the elements of the Hessian matrix, obtained by taking the second derivatives of the total energy with respect to the atomic positions, are linked to the strain gradient material constants.

Whale baleen is a keratin-based biological material; it provides life-long (40-100 years) filter-feeding for baleen whales in place of teeth. This study reveals new aspects of the contribution of the baleen's hierarchical structure to its fracture toughness and connects it to the unique performance requirements, which require anisotropy of fracture resistance. Baleen plates are subjected to competing external effects of hydration and varying loading rates and demonstrate a high fracture toughness in transverse loading, which is the most important direction in the filtering function; in the longitudinal direction, the toughness is much lower since delamination and controlled flexure are expected and desirable. The compressive strength is also established and results support the fracture toughness measurements: it is also highly anisotropic, and exhibits a ductile-to-brittle transition with increasing strain rate in the dry condition, which is absent in the hydrated condition, conferring impact resistance to the baleen. Using 3D-printing prototypes that replicate the three principal structural features of the baleen plate (hollow medulla, mineralized tubules, and sandwich-tubular structure) are created, and the role of its structure in determining its mechanical behavior is demonstrated. These findings suggest new bioinspired engineering materials.

One of the common architectures in natural materials is the helicoidal (Bouligand) structure, where fiber layers twist around a helical screw. Despite the many studies that have shown the existence of Bouligand structures, methods for nanoscale structural characterization and identification of fiber mechanical properties remain to be developed. In this study, we used the exocuticle of Cotinis mutabilis (a beetle in the Cetoniinae) as a model material to develop a new experimental-theoretical methodology that combines atomic force microscopy-based nanoindentation and anisotropic contact mechanics analysis. Using such methodology, we studied both the helicoidal structure and the mechanical properties of its constituent fibers. The twist angle between the layers was found to be in the range of 12°–18° with a pitch size of 220 nm for the helicoidal pattern. In addition, the constituent fiber diameter was measured to be approximately 20 nm, which is consistent with the fiber diameters found in helicoids of other arthropod species. The longitudinal, transverse, and shear modulus of the nanofiber were determined to be 710 MPa, 70 MPa, and 90 MPa, respectively. The established experimental-theoretical methodology promises to be a useful tool for nanoscale characterization of helicoidal and other structures found in biological materials.

Monolithic bulk metallic glasses (BMGs) exhibit a unique combination of mechanical properties, such as high strength and large elasticity limits, but the lack of ductility is considered the main Achilles' heel of BMG systems. To increase the competitiveness of BMGs vis-a-vis conventional structural materials, the problem of catastrophic failure via intense plastic strain localization ('shear banding') has to be addressed. Recent experimental observations suggest that the addition of structural heterogeneities, in the form of crystalline particles, to BMG systems hinders the catastrophic propagation of shear bands and leads to enhanced ductility. These structural heterogeneities can be introduced by either forming BMG composites, where second-phase crystalline particles accommodate applied loads via martensitic transformation mechanisms, or developing glassy alloys that precipitate crystalline particles under deformation, a process by which further deformation can be sustained by twinning mechanisms in the crystalline phase. In this work, we present a non-linear continuum model capable of capturing the structural heterogeneity in the glassy phase and accounting for intrinsic work hardening via martensitic transformations in second-phase reinforcements in BMG composites and deformation twinning in precipitated crystalline particles. Simulation results reveal that in addition to intrinsic work hardening in the crystalline phase, particle size greatly affects the overall mechanical behavior of these BMG systems. The precipitation of crystalline particles in monolithic BMGs yields two-phase microstructures that promote more homogeneous deformation, delay the propagation of incipient shear bands, and ultimately result in improved ductility characteristics.