Additive manufacturing (AM) based on Laser Powder Bed Fusion (LPBF) enables the fabrication of complex architected materials such as Triply Periodic Minimum Surface (TPMS) lattices, but introduces significant residual stresses and microstructural heterogeneity that strongly influence fatigue performance. This study investigates fatigue crack growth (FCG) in TPMS structures fabricated with LPBF technology by integrating multiscale modeling and fracture mechanics. Residual stresses are quantified through coupled thermo-mechanical finite element simulations, employing both layer-by-layer and path-dependent modeling approaches, while experimental fatigue crack-growth parameters are obtained from compact-tension (CT) specimens in as-built (AB) and T5 heat-treated, stress-relieved (SR) specimens conditions. The influence of printing direction, heat treatment, relative density, and scanning strategy is systematically evaluated through non-planar crack-growth simulations applied to IWP-TPMS lattices. Results show that vertically built structures accumulate higher tensile residual stresses, leading to increased effective stress intensity and shorter fatigue lives. Heat treatment reduces these stresses by similar to 25%-35%, consistently extending fatigue life. Higher relative density (50%) architectures exhibit stronger sensitivity to printing orientation and T5 treatment due to increased stiffness and constrained ligament networks. AM scanning strategy shows minimal influence, except for 0 degrees/90 degrees and 45 degrees/-45 degrees patterns, which yield slightly lower tensile stress magnitudes, which in turn increases fatigue life. The proposed computational framework accurately captures fatigue crack-growth paths and life predictions, agreeing markedly well with experimental findings, offering new insight into how printing direction, heat treatment, and relative density collectively govern fatigue performance in TPMS architectures.

The present study demonstrates the corrosion inhibition potential of three nitrogen-based cationic surfactant molecules (AMCs) for P110 carbon steel (P110 CS) in 20% H2SO4 solution. The corrosion inhibition efficiency (%IE) of the studied surfactants was demonstrated using electrochemical (OCP, PDP, and EIS), scanning electron microscopy (SEM), and DFT-based computational studies. The outcomes suggest that their inhibition efficiencies increase with increasing hydrophobic character in the form of alkyl chain(s). The surfactant molecule (AMC-3), having two long alkyl chains, manifests the best inhibition efficiency, and AMC-1, without any such alkyl chain, manifests the lowest efficiency. Their %IE followed the sequence (PDP data at 100 ppm): AMC-3 (96.44%) > AMC-2 (93.39%) > AMC-1 (89.78%). Potentiodynamic polarization (PDP) study suggests that they retard anodic and cathodic Tafel reactions and serve as mixed-type corrosion inhibitors. Electrochemical impedance spectroscopy (EIS) study suggests the AMCs become effective by creating a barrier for the charge transfer process through their adsorption at the interface of metal and electrolyte. The adsorption mode of corrosion protection was also supported by SEM analyses, where a significant improvement in the surface morphology of the P110 CS surface was observed in the presence of AMCs, especially in the presence of AMC-3. Their adsorption on the P110 CS surface followed the Langmuir isotherm model. DFT-based quantum chemical calculations show that AMCs interact with the P110 CS surface through physicochemisorption mechanisms where long alkyl chains (or hydrophobicity) play a crucial role in their adsorption.

The mechanical properties of cellular structures derived from spinodal decomposition and triply periodic minimal surfaces (TPMSs) are gaining interest for lightweight metamaterials, particularly with advances in additive manufacturing. While the compressive and flexural performance of periodic cellular structures has been widely studied, the influence of stochasticity in microstructural orientation remains insufficiently investigated. This study investigates the mechanical response of sheet-based cellular structures, including TPMS-based periodic, TPMS-based stochastic, and spinodal-based structures. TPMS-based stochastic structures are generated using Gyroid and Diamond topologies through random rotation of unit cells within dispersed control volumes, whereas spinodal-based structures are formed using the Gaussian random field method. Experimental and numerical analyses are performed to evaluate the stress–strain responses under uniaxial compression and three-point bending loadings. Numerical results indicate that periodic TPMS structures exhibit up to 58% and 61% higher compressive yield and plateau strengths, respectively, and up to 51% higher flexural strength than their stochastic counterparts. The numerical predictions for stochastic structures are validated experimentally, demonstrating good agreement. All analyzed stochastic cellular structures display similar compressive and flexural responses, with Gyroid-based stochastic structure showing slightly better properties. Overall, TPMS-based stochastic design approach produces stochastic structures with enhanced compressive and flexural properties compared with spinodal-based structures.

Anodization of 304 stainless steel in ammonium-fluoride-based electrolytes produced thick (similar to 3 mu m) Fe-Cr-O-F oxide films whose chemistry and corrosion behavior were examined before and after postanodization heat treatment. XPS and XRD revealed mixed-valence Fe2+/Fe3+ oxides with Cr3+ incorporation in the as-formed layer, which was highly hydrated and fluoride-rich. Heat treatment at 450 degrees C induced defluorination, dehydration, and crystallization into a dense spinel of Fe3O4-Fe2O3. Electrochemical testing in borated water (2 ppm Li, 1,000 ppm B) and 3.5 wt% NaCl showed that corrosion response depends strongly on oxide composition and formation voltage. The heattreated oxide exhibited the lower current density (similar to 0.08 mu A/cm(2)) and higher resistance (similar to 7 & times; 105 Omega & centerdot;cm(2)) in borated water, whereas in chloride solution, performance varied nonmonotonically with anodizing voltage due to competing effects of porosity, cracking, and localized breakdown resistance. These results demonstrate that anodization markedly alters the Fe-Cr oxide chemistry, and corrosion behavior is governed by fluoride content, hydration, and film integrity.

Graphene-based high-density polyethylene (HDPE) nanocomposites have lately emerged as a promising route to enhance the mechanical properties of HDPE for high-performance engineering applications. This review critically examines the mechanical properties of HDPE/graphene nanocomposites, with emphasis on the influence of graphene size, type, concentration, and surface modification. Results indicate that the addition of graphene, even at very low concentrations, can enhance HDPE mechanical properties, including tensile and flexural moduli, and to a lesser extent the tensile and flexural strength. However, these enhancements depend on uniform dispersion and strong interfacial interactions within the polymer, where agglomeration can lead to significant reductions in mechanical properties. While ductility and impact resistance generally decrease with graphene addition, strategies such as graphene functionalization and compatibilizers can mitigate these drawbacks. Results also show that although larger graphene flake sizes better enhance the mechanical properties at lower concentrations, they lead to reductions in properties at higher concentrations due to increased agglomeration of graphene. Contrarily, impact resistance is higher with smaller graphene flake sizes. Finally, current challenges, including scalable dispersion methods, property trade-offs, and industrial processing compatibility, are discussed, and future research directions are outlined to facilitate their broader adoption in commercial applications, such as packaging and pipes.

The long-term performance of orthopaedic implants is governed by coupled interactions between mechanical loading, bone biology, and implant design. Cellular interactions at the bone–implant interface regulate bone regeneration and osseointegration, thereby influencing the load transferred to the surrounding bone tissue and consequently determining peri-implant bone response. Bone remodeling is a dynamic, strain-adaptive process in which resorption and formation are continuously adjusted in response to mechanical stimuli, making it central to bone loss associated with implant-induced stress shielding. This review synthesizes current understanding of strain-adaptive bone remodeling, with emphasis on mechano-biological principles and remodeling algorithms used to quantitatively describe bone adaptation in response to changes in mechanical environment. Applications of these algorithms are discussed, including studies integrating remodeling predictions with topology optimization to enhance bone response and implant performance. Moreover, the effects of loading-related factors such as loading frequency, number of loading cycles, and rest periods on bone mechano-adaptation are analyzed. By integrating biological, mechanical and computational perspectives, this study provides a broader understanding of bone biomechanical behavior and outlines key considerations for advancing predictive approaches to peri-implant bone adaptation.

Hydrogen-assisted cracking remains a critical threat to the durability and safety of metallic structures, arising from the interaction of diffusible hydrogen with the microstructure, which weakens interatomic cohesion and promotes premature fracture. This work presents a novel chemo-mechanical modeling framework that integrates material deformation, stress-assisted hydrogen diffusion, and hydrogen-induced degradation of mechanical properties. A localizing gradient damage enhancement is employed to regularize softening responses and produce sharply localized damage zones that correspond to macroscopic cracks, thereby eliminating the spurious effects typically observed in conventional gradient damage models. The approach delivers physically consistent, mesh-objective crack propagation and seamless integration into standard finite element workflows without requiring predefined crack paths or cohesive interfaces. The framework is implemented using a staggered solution strategy to ensure stable convergence even in nonlinear regimes and is validated through three representative case studies: a cracked plate under hydrogen charging, compact tension testing subjected to internal hydrogen-assisted cracking, and single-edge notch tension tests in sour environments. The simulations reproduce key experimental trends and accurately capture the interplay among hydrogen transport, stress fields, and damage localization. Owing to its predictive capability, numerical robustness, and ease of implementation, the proposed method provides a practical computational tool for assessing hydrogen-induced fracture and structural integrity in hydrogen-rich environments.

Accurate prediction of post-implantation bone remodeling is essential for preserving bone stock, mitigating aseptic loosening, and guiding implant design. Classical strain-adaptive bone remodeling models, derived from Wolff’s law, relate bone density solely to local strain energy per unit mass. However, in-vivo evidence shows that bone adaptation is also regulated by loading frequency, number of loading cycles, and rest periods between loading sessions, factors that strongly influence fluid-induced shear stresses, cellular desensitization, and mechanosensitivity recovery. In this study, a modified strain-adaptive remodeling model that explicitly incorporates these load-related parameters was developed. The model was implemented on a tibia reconstructed from computed tomography data and implanted with a tibial tray. A time-varying loading protocol was defined to mimic post-operative recovery and progressive activity restoration. Bone mineral density (BMD) changes were quantified in regions of interest (ROIs) within the medial and lateral condyles and distal to the implant stem. At two years post-implantation, the modified model predicted BMD reductions of 13.33%, 11.81%, and 1.13% in the medial, lateral, and distal ROIs, respectively, versus 38.09%, 35.77%, and 0.85% predicted by the original formulation. The modified algorithm reproduced both the magnitude and temporal evolution of BMD changes in closer agreement with clinical observations, whereas the classical strain-adaptive model substantially overestimated bone resorption and failed to capture observed remodeling trends. Incorporating load-related parameters into strain-adaptive bone remodeling and accounting for loading history markedly improves biological realism and predictive accuracy, supporting the proposed framework potential application in post-implantation bone remodeling analysis and implant design optimization.

Leakage in bolted pipe flange connections, particularly those involving materials with dissimilar stiffness like high-density polyethylene (HDPE) and steel, is a persistent challenge in infrastructure systems. This study investigates a computational framework for evaluating and improving the leak-tightness of HDPE flange assemblies by employing the tetra-parametric assembly method (TAM), which iteratively calculates non-uniform bolt load distribution. The approach accounts for key time- and temperature-dependent phenomena, including viscoelasticity and stress relaxation in HDPE, using a calibrated non-linear three-network (TN) constitutive model. Finite element analysis (FEA) is used to simulate the long-term mechanical response of HDPE connections under various isothermal conditions (23◦C, 40◦C, 60◦C, and 80◦C), revealing increased susceptibility to leakage at elevated temperatures due to loss of bolt preload. To reflect real-world operating conditions, an annual temperature profile representative of an above-ground piping system was applied to the model, enabling prediction of leak-tightness over a full year of service. The results highlight the importance of accounting for thermal and mechanical degradation over time and inform several bolt re-torquing strategies to mitigate leakage risks. The proposed framework offers practical guidelines for optimizing HDPE flange connection performance and provides engineers with a robust tool for improving the reliability of thermoplastic piping systems.

Lattices based on triply periodic minimal surfaces (TPMS), which are a class of architected cellular materials, have attracted significant attention lately, due to their prevailing multifunctional properties and due to the advancements in additive manufacturing technologies. However, TPMS lattices are computationally expensive to model explicitly when used in latticing various structures for enhanced mechanical properties. This study presents for the first time a macroscopic constitutive model that can predict the bulk anisotropic elastic-plasticdamage response of TPMS sheet-based lattices, including its numerical implementation using the finite element method. The proposed macroscopic constitutive model consists of a cubic symmetric elasticity model, a modified version of anisotropic Hill's plasticity yield surface with an associative flow rule, and an anisotropic damage model such that both the plasticity and damage models account for the asymmetric behavior of lattices under tension and compression loading conditions. The developed macroscopic constitutive modeling is validated through predicting the elastic-plastic-damage behavior of the Schoen's I-WP sheet-based TPMS lattice (IWP-s) at 28% relative density and Neovius sheet-based TPMS lattice (NEOV-s) at 25% relative density under various multi-axial loading conditions, where a very good match is obtained between the macroscopic models and the explicit micro-mechanics models of the lattices. In addition, validation is done on a cantilever beam problem that consists of homogenous distributions of TPMS sheet-based lattices where a very good match is found between the latticed beam's elastic and elastic-plastic-damage responses and the macroscopic models' predictions for both IWP-s and NEOV-s, while saving about 2778 times the computational time. This macroscopic continuum modeling framework helps in the development of computationally effective coupled elastic-plastic-damage constitutive models for various types of lattice metamaterials.

The Electrochemical anodization of stainless steels enables the fabrication of nanostructured oxide layers with high corrosion resistance and tunable functionality. Compared with conventional valve metals such as aluminum or titanium, stainless steels present greater complexity due to their multicomponent composition and stable passive films. Recent progress, including dual-step anodization, optimized electrolytes, and targeted post-treatments has made it possible to form robust, self-organized nanoporous oxides with controlled morphology and thickness. This review critically evaluates these advances, highlighting how processing parameters influence oxide composition, pore ordering, and long-term corrosion performance. The discussion integrates recent mechanistic insights with practical design strategies for catalytic, energy-storage, and protective applications. Remaining challenges related to phase stability, mechanical integrity, and scalability are identified, along with future opportunities for deploying anodized stainless steels in advanced electrochemical and energy systems.

Additive manufacturing (AM) offers unprecedented design freedom for complex metallic components, yet the unique material characteristics inherent to the process, including anisotropic microstructures, high residual stresses, and process-induced defects, pose a critical challenge to their long-term reliability in corrosive environments. Stress Corrosion Cracking (SCC) is a particularly significant threat, as the material features created by AM can profoundly influence material susceptibility to cracking. SCC arises from the intricate interplay between microstructure, stress, and environment. This article provides a comprehensive review of experimental findings and computational models of SCC across different additively manufactured alloy systems. It begins with an overview of commonly recognized mechanistic models to explain SCC, followed by an in-depth discussion of how various AM techniques, processing parameters, AM-induced material features, and post-processing treatments affect SCC susceptibility. Herein, experimental studies are systematically examined to assess how various factors influence SCC susceptibility. The review also summarizes the testing and characterization methods employed in these studies. Finally, the computational modeling landscape is examined, encompassing classical mechanistic frameworks and emerging multiphysics approaches. The article concludes by identifying key challenges and outlining future research directions that aim to advance predictive modeling capabilities and support the qualification of additively manufactured components.

Material jetting (MJ) photopolymers enable interface-rich digital materials, but predictive modelling remains challenging because of rate-dependent deformation, post-processing sensitivity, and interfacial fracture between mismatched rigid-compliant constituents. This study develops an experimentally grounded constitutive and interfacial failure framework for a Vero–Flex95 photopolymer pair, targeting interface-dominated applications such as interpenetrating phase composites (IPCs). Sensitivity analyses identified stable mechanical behavior after 16h of UV curing and 3 days of ambient aging. The rate-dependent bulk response was captured using a calibrated Three Network Viscoplastic (TNV) model based on tensile tests at four strain rates, incorporating a stress-based damage criterion to reproduce the full response under monotonic loading. Interfacial behavior was characterized using cohesive zone modelling (CZM) under Mode I and Mode II loading to capture crack initiation and propagation, with out-of-plane shear approximated from the Mode II response. The coupled framework was validated through quasi-static compression of a TPMS-based IPC, showing strong agreement with experiments and accurately predicting strain localization and progressive collapse. Overall, the framework links post-processing history to constitutive and fracture behavior and provides a predictive tool for multi-material systems governed by interfacial strength under monotonic, quasi-static loading, while broader cyclic effects and independent identification of Mullins-type softening remain beyond the scope of the present study

Coordination chemistry plays a significant role in corrosion science by clarifying the mechanics of interactions between inhibitor molecules and metal surfaces and using coordination compounds as effective corrosion inhibitors. The conventional corrosion inhibitors use their heteroatoms (N, O, S, and P) and electron-rich polar functional groups to coordinate with the metal surface. The polar substituents also influence the coordination and bonding efficiency of entire inhibitor molecules through resonance and inductive effects, which affect the electron density at the coordination site or sites. This review comprehensively illustrates the contribution of coordination chemistry principles and theories in corrosion inhibitors' adsorption and bonding. Numerous coordination materials, including MOFs (metal-organic frameworks), OMCs (organometallic compounds), CPs (coordination polymers), and their derivatives and composites, have emerged as next-generation corrosion inhibitors. The article discusses the advantages of coordination materials, including high surface area, adequate coverage, and self-healing potential, as alternatives to toxic corrosion inhibitors. It highlights the corrosion inhibition potential of emerging materials like MOF-MXenes composites and their self-healing properties, emphasizing the importance of coordination chemistry in developing sustainable corrosion inhibitors. This also underscores the growing relevance of coordination chemistry in developing sustainable, high-performance corrosion inhibitors tailored for modern industrial demands.

Hygromorph biocomposites based on natural fibers exhibit moisture induced strains that can be exploited for passive actuation, but at the cost of degraded mechanical properties over time. Existing studies focused on conventional quad laminates, even though such layups impose design restrictions. Double-double (DD) laminates, constructed from repeated four ply blocks offer a much flexible design space with only two fiber angles and a repetition parameter. However, their hygromorph behavior has not been explored. This work investigates the curvature response of DD laminates made from unidirectional flax/epoxy laminates. Classical Laminate Theory (CLT) is used to map bending and twist authorities over the full design space using an equivalent bending energy measure and a twist ratio. Steady state in plane moisture diffusivities are derived analytically, together with an anisotropy index that reveals combinations of certain fiber angles maximize bending and maintain near isotropic diffusion. A transient through thickness diffusion model is developed to predict time dependent curvature histories. Curvature based homogenization measures are also introduced to quantify convergence of bending magnitude and twist ratio with the number of repeats. Laminate-level analysis show that selective DD layups deliver higher bending authority and greater in plane shear stiffness than selected quad baselines.

The operational integrity of oil country tubular goods (OCTG)-grade alloys, specifically those used for production casing in sour service applications, is significantly influenced by sulfide stress cracking (SSC) due to hydrogen sulfide (H2S)-rich environments. Accurate prediction of burst pressure, therefore, becomes more challenging for ensuring safe operation and for advancing fitness-for-service (FFS) assessment methodologies. A key factor often neglected in conventional evaluations is the presence of residual stresses introduced during manufacturing and fabrication. This study numerically investigates the influence of residual stresses on the burst performance of API 5CT C110, a high-strength, low-alloy carbon steel commonly used in deep sour condensate wells within the petroleum industry. We employ a coupled deformation-diffusion-fracture phase-field framework, specifically calibrated to model pipe burst behavior under sour environment conditions, including internal pressure and exposure to H2S-containing aqueous test solutions. To represent manufacturing-induced stresses, residual stress fields, quantified in representative pipe segments, are incorporated into the finite element model using a thermo-mechanical equivalent loading approach. The resulting initial stress field is then mapped onto the pipe burst simulations to account for pre-existing stress distributions realistically. The findings reveal how residual stresses alter the crack driving force and, ultimately, influence crack initiation/growth, leading to pipe burst failure.

The swift transition to sustainable energy has heightened demand for high-performance, safe, and environmentally responsible battery technologies. Zn₋, Mg₋, Na₋, Al₋, Fe₋, organic, and bio-based systems offer several advantages over traditional resource-intensive and toxic alternatives. However, their practical implications are significantly challenged by their susceptibility to electrochemical corrosion, which adversely affects their efficiency, longevity, safety, recyclability, and reversibility. Corrosion is one of the most significant and persistent barriers to the development of next-generation energy storage systems. This review comprehensively presents unified mechanisms of corrosion across diverse sustainable battery systems, with a detailed account of pitting, uniform, galvanic, intergranular, and passivation-related degradation pathways. The article presents a unique comparison of the degradation mechanisms of Zn, Al, Mg, and other anodes in different electrolytes. Corrosion mitigation strategies, including surface passivation, surface engineering, alloying, use of surfactants and polymer-based films, ionic liquids, deep eutectic solvents, metal–organic frameworks, heterocycles, and bio-based multifunctional corrosion inhibitors, have been comprehensively surveyed. These inhibitors suppress the increase in cycle life, achieving inhibition efficiencies of over 90

Additive manufacturing (AM) offers several unique advantages, including greater efficiency, design flexibility, and microstructural refinement. However, the corrosion resistance of AM-produced alloys remains a field of debate owing to the effects of printing parameters on porosity, microstructural properties, and passive film stability. The present study reports the printing of 316 L stainless steel (SS316L) specimens using the laser powder bed fusion (LPBF) technique and the subsequent testing of their corrosion resistance in 0.6 M NaCl, H2O2 (0.01 M and 0.5 M), and Na2SO4 (25 mM) solutions. The specimens were produced under a wide range of printing parameters, including scanning speed (500-1100 mm/s), laser power (150-330 W), and hatch distance (0.09-0.125 mm), with varying hardness, electrochemical behavior, porosity, and grain morphology and size. The results showed that an appropriate combination of scanning speed and laser power is crucial for achieving a refined microstructure and reduced porosity. The outcomes of electrochemical (EIS and PDP) studies suggest that AM-printed alloys exhibit better corrosion resistance than wrought 316 L, with specimen #19 demonstrating the best polarization resistance (Rp) and the lowest current density (Icorr). The specimen was fabricated at a laser power of 230 W, a scan speed of 1100 mm/s, and a hatch distance of 0.09 mm, respectively. The results further show that, in NaCl solution, porosity is a crucial factor in pitting initiation. On the other hand, in H2O2 solution, an increase in peroxide concentration stabilizes the passive films.

Traditional architected dense interpenetrating phase composites (IPCs) are known to exhibit high structural weight, high manufacturing complexity and cost, anisotropic behavior, and unavoidable interfacial debonding between the phases, resulting from the mismatch in their properties, which limits their performance. To address these limitations, this study designed, additively manufactured, and tested light, strong, and tough isotropic, open-cell architectures where mechanical properties are governed by lattice topological properties rather than individual phase material types in IPCs. Two novel classes of interpenetrating and hierarchical hybrid-lattice (IPH) metamaterials were developed using level-set approximation equations of the Primitive (P), Face-centered rhombic dodecahedron (FRD), and Gyroid (G) architectures, inspired by triply periodic minimal surfaces (TPMS) and spinodal-like phase decomposition in a dense material: self-similar and self-dissimilar interpenetrating-lattice systems. Using a material-scale phases-cell size ratio of at least 10:2, quasi-static compression tests showed that the isotropic P-G-FRD design achieved a similar to 22% increase in specific modulus, while the spinodal-like counterpart showed similar to 68.2% higher specific strength and similar to 16% higher specific energy absorption over the isotropic uniform G lattice. Flexural testing revealed that the uniform P-latticed beam was highly prone to rapid crack propagation, whereas all IPH metamaterials effectively deflected cracks and delayed failure. For instance, the isotropic P-G-FRD latticed beam achieved twice the failure strain of the uniform P lattice, and up to a 97.7% increase in specific flexural energy absorption was attained compared to the best-performing self-similar (P-P) latticed beam, with no penalty in weight. Impact tests showed that the self-similar isotropic IPH lattice with a spinodal-like macro-lattice architecture achieved the highest impact toughness, increasing the specific impact energy absorption by 103.9% compared to the uniform P lattice, while maintaining the same weight. This new multi-scale interpenetrating lattice design can be applied in building engineering as a lightweight, high-strength, and energy-absorbing structural system for seismic-resistant components, impact-resistant panels, and modular floor or wall cores. This has been demonstrated in the current work, numerically.