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If we look at the historical evolution of architecture - from the massive pyramids of Egypt to the framed structures of Greek and Roman construction, to the lighter Gothic vaulting and eventually modern architecture of the twentieth century - we see a continuous, almost linear progression from solid mass construction to diaphanous skins of glass and steel.
Book
Imperfection‐Enabled Strengthening of Ultra‐Lightweight Lattice Materials
Lattice materials are an emerging family of advanced engineering materials with unique advantages for lightweight applications. However, the mechanical behaviors of lattice materials at ultra‐low relative densities are still not well understood, and this severely limits their lightweighting potential. Here, a high‐precision micro‐laser powder bed fusion technique is dveloped that enables the fabrication of metallic lattices with a relative density range much wider than existing studies. This technique allows to confirm that cubic lattices in compression undergo a yielding‐to‐buckling failure mode transition at low relative densities, and this transition fundamentally changes the usual strength ranking from plate > shell > truss at high relative densities to shell > plate > truss or shell > truss > plate at low relative densities. More importantly, it is shown that increasing bending energy ratio in the lattice through imperfections such as slightly‐corrugated geometries can significantly enhance the stability and strength of lattice materials at ultra‐low relative densities. This counterintuitive result suggests a new way for designing ultra‐lightweight lattice materials at ultra‐low relative densities.
This study identifies different compressive failure modes of cubic lattices with different relative densities and proposes a novel imperfection‐enabled strengthening mechanism of ultra‐lightweight lattice materials. Geometric imperfections are proven to be advantageous in enhancing the stability and strength of lattice materials at ultra‐low relative densities, which suggests a new way to strengthen ultra‐lightweight lattices via introducing imperfections for buckling prevention.
Journal Article
Nanocellulose‐MXene Biomimetic Aerogels with Orientation‐Tunable Electromagnetic Interference Shielding Performance
Designing lightweight nanostructured aerogels for high‐performance electromagnetic interference (EMI) shielding is crucial yet challenging. Ultrathin cellulose nanofibrils (CNFs) are employed for assisting in building ultralow‐density, robust, and highly flexible transition metal carbides and nitrides (MXenes) aerogels with oriented biomimetic cell walls. A significant influence of the angles between oriented cell walls and the incident EM wave electric field direction on the EMI shielding performance is revealed, providing an intriguing microstructure design strategy. MXene “bricks” bonded by CNF “mortars” of the nacre‐like cell walls induce high mechanical strength, electrical conductivity, and interfacial polarization, yielding the resultant MXene/CNF aerogels an ultrahigh EMI shielding performance. The EMI shielding effectiveness (SE) of the aerogels reaches 74.6 or 35.5 dB at a density of merely 8.0 or 1.5 mg cm–3, respectively. The normalized surface specific SE is up to 189 400 dB cm2 g–1, significantly exceeding that of other EMI shielding materials reported so far.
Oriented biomimetic hybrid cell walls of nanocellulose‐MXene aerogels for tunable electromagnetic interference shielding and mechanism are represented by a yin‐yang symbol. Herein, the blue and red regions in the symbol correspond to angles with a smaller and larger transmission of the incident EM waves, respectively.
Journal Article
Research progress on microstructure tuning of heat-resistant cast aluminum alloys
With development of present energy-saving society, lightweight and green development in the automotive and aerospace industries have put forward urgent demands for heat-resistant cast aluminum alloys. Present cast aluminum alloys are of lightweight and have excellent mechanical properties when serving in ambient environment. However, when serving at temperatures of 200–300 ℃ or even higher, the alloys inevitably soften and the high-temperature mechanical properties decline rapidly, hardly meeting the requirements for high-performance equipments. This paper summarizes the development process of classic heat-resistant aluminum alloys, especially the microstructural characteristics of heat-resistant cast aluminum alloys in the past decade, and reviews the current microstructure tuning strategies of heat-resistant aluminum alloys from the aspects of intrinsic heat resistance of the second phases, phase interface modification, diffusion-controlled phase transition, grain boundary stabilization and composite material design. Finally, we propose the prospects for the future development of heat-resistant aluminum alloys.
Graphical abstract
Journal Article
Recent progress of aluminum alloys and aluminum matrix composites produced via laser powder bed fusion: a review
Al alloys and aluminum matrix composites (AMCs) are characterized by high specific strength, high specific modulus, and low density. As one of the most promising advanced lightweight materials, Al alloys and AMCs are widely used in high-speed railway, aerospace, defense, and other cutting-edge fields. However, with the urgent demand for lighter and more complex structures in these high-tech fields, traditional processing methods have shown huge limitations, such as long manufacturing process, low material utilization, restricted design and structure of parts. Fortunately, the rapid development of additive manufacturing technology in recent years has greatly expanded the flexibility of design and manufacturing. As a representative technology of metal additive manufacturing, laser powder bed fusion (LPBF) has outstanding advantages such as high accuracy, high material utilization and short production cycle. LPBF of Al alloys and AMCs is an effective method for producing complex and lightweight structural parts, however, at the meantime, it also faces huge challenges. In this article, the current research status of the LPBF processed Al alloys and AMCs are reviewed with main focus on powder preparation, LPBF technology and subsequent treatments.
Journal Article
Recent innovations in laser additive manufacturing of titanium alloys
Titanium (Ti) alloys are widely used in high-tech fields like aerospace and biomedical engineering. Laser additive manufacturing (LAM), as an innovative technology, is the key driver for the development of Ti alloys. Despite the significant advancements in LAM of Ti alloys, there remain challenges that need further research and development efforts. To recap the potential of LAM high-performance Ti alloy, this article systematically reviews LAM Ti alloys with up-to-date information on process, materials, and properties. Several feasible solutions to advance LAM Ti alloys are reviewed, including intelligent process parameters optimization, LAM process innovation with auxiliary fields and novel Ti alloys customization for LAM. The auxiliary energy fields (e.g. thermal, acoustic, mechanical deformation and magnetic fields) can affect the melt pool dynamics and solidification behaviour during LAM of Ti alloys, altering microstructures and mechanical performances. Different kinds of novel Ti alloys customized for LAM, like peritectic α-Ti, eutectoid (α + β)-Ti, hybrid (α + β)-Ti, isomorphous β-Ti and eutectic β-Ti alloys are reviewed in detail. Furthermore, machine learning in accelerating the LAM process optimization and new materials development is also outlooked. This review summarizes the material properties and performance envelops and benchmarks the research achievements in LAM of Ti alloys. In addition, the perspectives and further trends in LAM of Ti alloys are also highlighted.
Substantive review of innovations in methodology, process and materials of AM Ti alloys.
Novel titanium alloys designed for laser additive manufacturing.
Machine learning assisted alloy design and process optimization.
Field-assisted additive manufacturing for titanium alloys fabrications.
Journal Article
Heat-resistant Al alloys: microstructural design and microalloying effect
Lightweight strategy is essential for the development of transportation vehicles and aerospace industries. As a type of lightweight material, high-strength aluminum alloys are limited to service temperatures below 200 °C due to the rapid coarsening of strengthening nano-precipitates, which cannot satisfy the increasing demands of practical applications. High-temperature applications beyond 250 °C become the bottle-neck problem of Al alloys. In this paper, we review existing literature on the improvement of high-temperature performance of aluminum alloys by stabilizing nano-precipitates. On the basis of atomic-scale microstructure regulation, several design strategies, such as interface segregation, co-precipitation, core/shell structure, and interstitial ordering, have been proposed, resulting in the development of a number of heat-resistant Al alloys for use at 300–400 °C. Moreover, the fundamental theories of solid-state phase transformation, especially precipitation aging and coarsening, are correspondingly advanced on the frontiers of science.
Journal Article
Heterostructured metal matrix composites for structural applications: a review
Metal matrix composites (MMCs) with homogeneous structures (i.e., reinforcements with a uniform size are randomly dispersed in the metal matrix with a uniform grain size distribution) exhibit a strength-ductility/toughness tradeoff, which greatly hinders their engineering applications. Heterostructured metal matrix composites (HSMMCs) are regarded as an emerging class of MMCs consisting of heterogeneous zones with dramatically different attributes in the metal matrix, reinforcement and interface, relative to their conventional homogeneous counterparts, endowing them with the excellent combination of strength and ductility/toughness. These superior mechanical properties are enabled by activating extra strengthening and intrinsic/extrinsic toughening mechanisms induced by heterostructures. In the review, particular emphasis is given to the design principles of HSMMCs from the view of toughening mechanisms. The classification criteria of heterogeneity design are proposed based on the constituents of MMCs, including matrix heterogeneity, reinforcement heterogeneity, interface heterogeneity, and combined heterogeneity (a combination of two or more constituents aforementioned). In the combined heterogeneity design, the matrix & reinforcement heterogeneity design is specially named architecture design due to the orderly spatial arrangement of matrix and reinforcement. We then examine each of the diverse heterostructures, particularly, their fabrication methods, mechanical properties and strengthening & toughening mechanisms in the HSMMCs. Afterwards, we review the typical structural applications of MMCs in aerospace, aviation and transportation. Finally, directions for future research in the field of HSMMCs are proposed.
Journal Article
A Review on Lightweight Metal Component Forming and its Application
The present research focused on reviewing forming technology and inspired various method forming processes for different lightweight materials. Nowadays, to improve modern automobiles’ fuel economy while preserving safety and efficiency, advanced materials are essential. Since accelerating a lighter object requires less energy than a heavier one, lightweight materials offer great potential to improve vehicle performance. Innovative forming technologies are discussed concerning each approach and their contribution to lightweight material application. New metal forming methods are implemented to fulfill lightweight material applications in various fields.
Journal Article
Recent progress on cast magnesium alloy and components
The application of cast magnesium alloy components is increasing in recent years, especially in the new energy automotive and transportation industries. As component application scenarios become increasingly complex, the performance of cast magnesium alloys needs to be further enhanced. Significant progress has been made in casting technology and the design of cast magnesium alloys. In addition, some new application of cast magnesium alloy components is also developed recently. This paper provides an overview of the current status of high-performance cast magnesium alloys, including the alloy design, casting techniques, control of casting defects, and applications of cast magnesium alloys. Based on the issues and challenges identified here, some future research directions on cast magnesium alloys are suggested.
Journal Article