Lectures Notes on Advanced Structured Materials 2 (Advanced Structured Materials, 203)

The postgraduate seminar series on advanced structured materials is designed to facilitate teaching and informal discussion in a supportive and friendly environment. The seminar provides a forum for postgraduate students to present their research results and train their presentation and discussion skills. Furthermore, it allows for extensive discussion of current research being conducted in the wider area of advanced structured materials. Doing so, it builds a wider postgraduate community and offers networking opportunities for early career researchers. In addition to focused lectures, the seminar provides specialized teaching/overview lectures from experienced senior academics. The 2023 Postgraduate Seminar entitled “Advanced Structured Materials: Development - Manufacturing - Characterization – Applications” was held from 20th till 24th February 2023 in Barcelona. The presented postgraduate lectures had a strong focus on polymer mechanics, composite materials, and additive manufacturing. Preface Contents Overview Lectures Continuum Mechanics – Material Independent and Dependent Equations 1 Some Historical Remarks 1.1 References 1.2 Important Stages in the Development of Continuum Mechanics 2 Continuum Mechanics – Three-Dimensional Case 2.1 Material Independent Equations 2.2 Material Dependent Equations 2.3 Some Comments Concerning Tensor Calculus 3 One-Dimensional and Two-Dimensional Continuum Mechanics 4 Concluding Remarks References Mechanical Behavior of Classical Sandwich Beams 1 Introduction 2 Basic Mechanical Load Cases 2.1 Bending Load 2.2 Tensile/Compressive Load 2.3 Shear Load 3 Technical Sandwich 3.1 Bending Load 3.2 Tensile/Compressive Load 3.3 Shear Load 3.4 Bending Deformation References Classical Solidification Structures in Single-Step Metal Additive Manufacturing 1 Introduction 2 Solidification Structures 2.1 Knowledge from Classical Processes 2.2 Single-Step AM 3 Summary References Additive Manufacturing as a Key Driver in the Mobility of Tomorrow 1 Introduction 2 Additive Manufacturing for Mobility Applications 2.1 Additive Manufacturing of Plastic Components 2.2 Example of a Hybrid Material Made of Plastic and Metal (Copper and Steel) 3 Practical Example of a Metallic Additive Component 4 Discussion 5 Conclusion References Postgraduate Lectures Experimental Analysis of Strain and Thermal Behaviour on 3D Printed Flexible Auxetic Structures 1 Introduction 2 Method 2.1 Unit Cell Geometrical Properties 2.2 Preparation of Samples and Test Setup 2.3 Post-processing of Obtained Data 2.4 Determination of Dynamic Poisson's Ratio 3 Results and Discussion 3.1 Strain and Temperature Distribution 3.2 Determination of Dynamic Poisson's Ratio nuν 4 Conclusion References Crack Evaluation of Ozone-Aged Elastomers 1 Introduction 2 Material and Artificial Ageing 2.1 Material 2.2 Artificial Ageing Strategy 3 Detection of Cracks 3.1 Cracks on the Surface 3.2 Crack Depths in the Cross-Section 4 Kinetic Approach for Evolution of Cracks 5 Discussion 6 Conclusion and Outlook References Selective Laser Sintered Pipe Specimen Under Torsional Load: Experimental Investigations and Material Modeling 1 Motivation 2 Experimental Methods 2.1 SLS Production Strategy 2.2 Torsion Specimen Design and Experimental Setup 3 Experimental Results 3.1 Kinematics of Pipe Specimen Under Torsional Load 3.2 Influence of the Building Direction on the Stress–Strain Curve 3.3 Influence of the Rate Dependency on the Stress–Strain Curve 3.4 Step Tests and Cyclic Tests 4 Material Modeling 4.1 Three-Parameter Model of Viscoelasticity 4.2 Relaxation Tests 4.3 Parameter Identification from Relaxation Test 4.4 Application of Parameter Set 5 Conclusion and Outlook References The Importance of Heat Conduction and Global Temperature Fields in the Laser Powder Bed Fusion Process 1 Introduction 2 Experimental Setup 2.1 Material and Machine 2.2 Samples and Test Program 3 Results and Discussion 4 Conclusion References Investigation of the Anisotropic Mechanical Behaviour of Short Carbon Fibre-Reinforced Polyamide 6 Fabricated via Fused Filament Fabrication 1 Introduction 2 State of the Art 2.1 Process-Related Anisotropy 2.2 Material-Related Anisotropy 2.3 Anisotropy of 3D Printed Samples Under Tensile Load 3 Investigation in Fibre Orientation 3.1 Experimental Set-up 3.2 Results and Discussion 4 Investigation of Interface Properties 4.1 Experimental Set-up 4.2 Results and Discussion 5 Summary and Outlook References Determination of the Fatigue Behaviour of Laser Powder-Bed Fused AlSi10Mg Specimens Using Surface and Heat Treatments 1 Introduction 2 Experimental Methods 2.1 Process Description of Sample Production 2.2 Overview of Post Treatments and Examinations 2.3 Process Description Machining 2.4 Process Description T5 Heat Treatment 2.5 Process Description Laser Polishing 2.6 Process Description Shot Peening 2.7 Process Description Slide Grinding 2.8 Fatigue Strength Test and Their Evaluation Methodology 2.9 Crack Origin Analysis 3 Results and Discussion 3.1 Wöhler Curves 3.2 Fracture Mechanism Based on SEM Images 4 Conclusions References Sorption of Fuels in Additively Manufactured Thermoplastic Polyurethanes 1 Introduction 2 Experimental Part 2.1 AM Material and Aviation Fuel 2.2 3D Printing of Specimens 2.3 Chemical Characterization 2.4 Testing Procedure 3 Results 3.1 Chemical Characterization 3.2 Behavior in Contact with Immersion Fluid 4 Discussion 5 Conclusions and Remarks References Distortion Compensation of Thin-Walled Parts by Pre-Deformation in Powder Bed Fusion with Laser Beam 1 Introduction 2 Methods 2.1 FE Model and Artifact Design 2.2 Refined Super Layer Approach 2.3 Non-Uniform Compensation Approach 2.4 Experimental Setup 3 Results and Discussion 3.1 Simulation Results 3.2 Validation Results 4 Conclusion References Investigation of the Thermophysical Properties of Porous Steel Components Made by Selective Laser Melting 1 Introduction 2 Methods 2.1 Parameter Study 2.2 Density Analysis 2.3 Transient Plane Source Method 3 Results 4 Discussion References Analysis of the Heating Behavior and the Strength of Hot Gas Welded Polyamides with 3D Contours Using an Immersing Nozzle System 1 The Hot Gas Welding Process 2 Nozzle Systems for Hot Gas Welding 3 Test Setup 3.1 Hot Gas Welding System 3.2 Top Nozzle System 3.3 Types of Tested Plate Specimens 3.4 Tested Polymers 4 Influence of the Heating Time on the Weld Strength Depending on the Inclination Angle 4.1 Plate Specimen Without Inclination Angle 4.2 Plate Specimen with 15° Inclination Angle 4.3 Plate Specimen with 30° Inclination Angle 4.4 Plate Specimen with 45° Inclination Angle 4.5 Plate Specimen with 60° Inclination Angle 5 Discussion of the Influence of the Inclination Angle on the Weld and Component Strength 5.1 Investigation of the Inclination Angle on a PA6-GF30 5.2 Investigation of the Plate Specimen Shape on a PA6-GF30 5.3 Investigation of the Inclination Angle on a PA66-GF35 5.4 Investigation of the Plate Specimen Shape on a PA66-GF35 5.5 Investigation of the Fracture Pattern of the Plate Specimen 6 Summary and Outlook References Simulation of Lattice Structures with Johnson–Cook Material and Damage Model 1 Introduction 2 Materials and Methods 2.1 Lattice Structure Modeling 2.2 Experimental Procedure 2.3 Manufacturing 2.4 Mechanical Testing 2.5 Drop Tower Test 3 Finite Element Modeling 3.1 Johnson–Cook Material Model 3.2 Johnson–Cook Failure Model 3.3 Simulation Setup 4 Results and Analysis 4.1 Experimental Results 4.2 Validation of the Test Setup 5 Finite Element Analysis 5.1 BCC Analysis 5.2 Vin Analysis 6 Conclusion References Effect of Residual Stress, Surface Roughness, and Porosity on Fatigue Life of PBF-LB AlSi10Mg 1 Introduction 2 Materials and Methods 2.1 Manufacturing Setup 2.2 Material Testing Setup 2.3 Modeling the Correction to the Stress Amplitude 3 Results and Discussion 3.1 Effect of Heat Treatment 3.2 Effect of Printing Parameters 3.3 Modeling the Influence Factors to Predict Fatigue Life 4 Conclusions References Elastoplastic Characterization of a Two-Component Epoxy-Based Structural Adhesive 1 Introduction 2 Materials and Methods 2.1 Static Tensile Tests 2.2 Torsion Tests 3 Results and Discussion 3.1 Static Tensile Tests 3.2 Torsion Tests 4 Conclusion 5 Outlook References Simulation of Infrared-Welded Short Fiber-Reinforced Thermoplastic Parts Based on Mori–Tanaka Homogenization Method 1 Introduction 2 Aim of the Study 3 Experimental Investigations 3.1 Manufacturing of the Infrared-Welded Components 3.2 Determination of the Matrix Properties 3.3 Quantification of the Local Fiber Fraction by TGA 4 Model 4.1 Homogenization 4.2 Reconstruction of the Fiber Orientation 4.3 Adapted Mori–Tanaka Model 5 Results 5.1 Validation of the Model 5.2 Application to a Component Simulation 6 Conclusion and Outlook References Analysis of Heterogeneous Ageing of HNBR O-Rings 1 Introduction 2 Material and Methods 2.1 Material 2.2 Methods 3 Results 3.1 Ftir 3.2 Compression Stress Relaxation 3.3 IRHD Microhardness 4 Conclusion References On the Characterisation and Modelling of the NR-BR Blend Under Harmonic Excitation Considering Self-heating Effect 1 Introduction 2 Material Characterisation 2.1 Hyperelastic Behaviour 2.2 Thermo-viscoelastic Behaviour 3 Modelling Approach 3.1 Kinematics 3.2 Material Model 3.3 Constitutive and Evolution Equations 3.4 Governing Equations and Numerical Implementation 4 Numerical Example 5 Conclusion References Thermal Analysis of Old Climbing Ropes 1 Introduction 2 Methodology 2.1 Dynamic Differential Scanning Calorimetry 2.2 Thermogravimetric Analysis 3 Results and Discussion 4 Conclusion References Notch Effect Under Cyclic Loading of Electrical Steel Strips 1 Introduction 1.1 Models to Account for Micro- and Macro-Notches Under Cyclic Loading 2 Results and Discussion 2.1 Material Investigated 2.2 Specimen Preparation and Edges Validation 2.3 Mechanical Properties of NO30-15 2.4 Stress-Controlled Fatigue Tests on NO30-15 2.5 Strain-Controlled Fatigue Tests on NO30-15 2.6 Discussion of the Quasi-Static Test Results 2.7 Discussion of Stress-Controlled Tests with Unnotched Specimens 2.8 Comparison of the Test Results with Methods for the Computational Evaluation of the Surface Influence 2.9 Discussion of Test Results with Notched Specimens 2.10 Application of the Local Concept to the Test Results of NO30-15 3 Summary References On the Ways to Numerically Implement the Two-Time-Scale Approach 1 Introduction 2 Constitutive Equations 2.1 Elastic Behavior 2.2 Inelastic Behavior 2.3 Application of the Two-Time-Scale Approach 3 Numerical Implementation 3.1 Backward Euler Method 3.2 Stress-Update Algorithm 3.3 Return-Mapping Algorithm 3.4 Comparison 4 Conclusion and Outlook References Development of Site Calibration Set for Prefixed Wall Transmitters of Environmental Monitoring Systems in Regulated Industries 1 Introduction 2 Methodology 3 Developments to be Done to the Calibration Set 4 Conclusion References