Pedro Gonçalves Coelho

Functionally Graded Materials (FGMs) can outperform their homogeneous counterparts. Advances in digitalization technologies, mainly additive manufacturing, have enabled the synthesis of materials with tailored properties and functionalities. Joining dissimilar metals to attain compositional grading is a relatively unexplored research area and holds great promise for engineering applications. Metallurgical challenges may arise; thus, a theoretical critical analysis is presented in this paper. A multidisciplinary methodology is proposed here to unify optimal design, multi-feed Wire-Arc Additive Manufacturing (WAAM), and image-based characterization methods to create structure-specific oriented FGM parts. Topology optimization is used to design FGMs. A beam under pure bending is used to explore the layer-wise FGM concept, which is also analytically validated. The challenges, limitations, and role of WAAM in creating FGM parts are discussed, along with the importance of numerical validation using full-field deformation data. As a result, a conceptual FGM engineering workflow is proposed at this stage, enabling digital data conversion regarding geometry and compositional grading. This is a step forward in processing in silico data, with a view to experimentally producing parts in future. An optimized FGM beam, revealing an optimal layout and a property gradient from iron to copper along the build direction (bottom–up) that significantly reduces the normal pure bending stresses (by 26%), is used as a case study to validate the proposed digital workflow.

Purpose: This study aims to achieve a “pseudo-ductile” behaviour in the response of hybrid fibre reinforced composites under uniaxial traction by solving properly formulated optimization problems. Design/methodology/approach: The composite material model is based on the combination of different types of fibres (with different failure strains or strengths) embedded in a polymer matrix. The composite failure under tensile load is predicted by analytical models. An optimization problem formulation is proposed and a Genetic Algorithm is used. Multi-objective optimization problems balancing failure strength and ductility criteria are solved providing optimal mixtures of fibres whose properties may come either from a pre-defined list of materials, currently available in the market, or simply assuming their continuum variation within predefined bounds, in an attempt to attain unprecedented performance levels. Findings: Optimal solutions of hybrid fibre reinforced composites exhibiting pseudo-ductile behaviour are presented. It is found that a fibre made from a material exhibiting relatively low stiffness combined with high strength is preferred for hybridization. Furthermore, the ratio of the average failure/critical strains between the low and high elongation fibres to be hybridized must be equal or greater than two. Originality/value: Typically, a ductile failure is an inherent property of metals, that is, their typical response curve after the linear (elastic) region exhibits a yielding plateau still followed by an increase in stress till collapse. In stark contrast, composite materials exhibit (under some loading conditions) brittle failure that may limit their widespread usage. Therefore, a “pseudo-ductility” in composites is valued and targeted through optimization which is the main original contribution here.

Bone scaffolds for tissue regeneration require an optimal trade-off between biological and mechanical criteria. Optimal designs may be obtained using topology optimization (homogenization approach) and prototypes produced using additive manufacturing techniques. However, the process from design to manufacture remains a research challenge and will be a requirement of FDA design controls to engineering scaffolds. This work investigates how the design to manufacture chain affects the reproducibility of complex optimized design characteristics in the manufactured product. The design and prototypes are analyzed taking into account the computational assumptions and the final mechanical properties determined through mechanical tests. The scaffold is an assembly of unit-cells, and thus scale size effects on the mechanical response considering finite periodicity are investigated and compared with the predictions from the homogenization method which assumes in the limit infinitely repeated unit cells. Results show that a limited number of unit-cells (3-5 repeated on a side) introduce some scale-effects but the discrepancies are below 10%. Higher discrepancies are found when comparing the experimental data to numerical simulations due to differences between the manufactured and designed scaffold feature shapes and sizes as well as micro-porosities introduced by the manufacturing process. However good regression correlations (R(2) > 0.85) were found between numerical and experimental values, with slopes close to 1 for 2 out of 3 designs.