The co-deposition of multiple powder feedstocks during metal additive manufacturing (AM) can be used to fabricate materials with spatially dependent properties, which can be engineered to contain different function- alities (i.e., functionally integrated materials, FIMs). Although the transition region that forms between dissimilar materials has been studied in detail, the influence of co-deposition on the resultant spatial phase distribution and associated mechanical behavior has heretofore not been reported. In this study, FIM samples transitioning from stainless steel (SS) 316 L to Haynes 282 Ni-based superalloy were deposited via directed energy deposition (DED). The FIM samples were compared to baseline, homogeneous single-alloy deposited samples using digital image correlation during tensile testing, together with microscopy, energy-dispersive X-ray spectroscopy, elec- tron backscattered diffraction, and thermodynamic modeling, to assess the performance of different co- deposition strategies. Each FIM sample exhibited a compositionally and microstructurally unique transition re- gion from SS 316 L to Haynes 282, which was found to have implications on the strain localization across the transition region during uniaxial tensile loading. Finer step sizes in co-deposition were found to minimize strain localization by avoiding sharp compositional interfaces in the transition region.

Metamaterials are engineered materials with unusual, unique properties and advanced functionalities that are a direct consequence of their microarchitecture. While initial properties and functionalities were limited to optics and electromagnetism, many novel categories of metamaterials that have applications in many different areas of research and practice, including acoustic, mechanics, biomaterials, and thermal engineering, have appeared in the last decade. This editorial serves as a prelude to the special issue with the same title that presents a number of selected studies in these directions. In particular, we review some of the most important developments in the design and fabrication of metamaterials with an emphasis on the more recent categories. We also suggest some directions for future research.

A hybrid Al-Al3Ni metallic foam was synthesized in-situ via directed energy deposition (DED) of Ni-coated Al 6061 powder, without the need for a foaming agent. Three-dimensional characterization via X-ray computed tomography shows that the foam contains approximately 61.5 % porosity and a high volume fraction of the Al3Ni phase (~60 vol. %) within the cell walls. This microstructure is notably distinct from the eutectic structure that is typically observed in conventionally processed Al-Ni alloys. To investigate the mechanical properties and deformation mechanisms of the Al-Al3Ni cell walls, in-situ micro-pillar compression was performed, and the results reveal a notable yield strength of 560 MPa and a compressive strain that exceeds 30 %. These properties are attributable to the presence of a high volume fraction of Al3Ni particles, in combination with the charac- teristics of the Al/Al3Ni interfaces. To provide insight into the deformation mechanisms in the cell walls we used in-situ mechanical testing, transmission electron microscopy and precession electron diffraction characterization, together with molecular dynamics simulations. Our results reveal two distinct mechanisms: uniform dislocation- based deformation of the Al alloy phase and localized deformation within the slip bands in the Al3Ni phase. The results further highlight the importance of the Al/Al3Ni interfaces in mechanical strengthening and the transfer of plastic deformation from the Al phase to the Al3Ni phase. At high mechanical loads, cracks form due to the large stress concentration at the slip bands and slip band intersections in the Al3Ni, giving rise to intragranular fracture of Al3Ni and finally interfacial debonding and cracking.

Architected metals and ceramics with nanoscale cellular designs, e.g., nanolattices, are currently subject of extensive investigation. By harnessing extreme material size effects, nanolattices demonstrated classically inaccessible properties at low density, with exceptional potential for superior lightweight materials. This study expands the concept of nanoarchitecture to dense metal/ceramic composites, presenting co-continuous architectures of three- dimensional printed pyrolytic carbon shell reinforcements and electrodeposited nickel matrices. We demonstrate ductile compressive deformability with elongated ultrahigh strength plateaus, resulting in an extremely high combination of compressive strength and strain energy absorption. Simultaneously, property-to-weight ratios outperform those of lightweight nanolattices. Superior to cellular nanoarchitectures, interpenetrating nanocom- posites may combine multiple size-dependent characteristics, whether mechanical or functional, which are radically antagonistic in existing materials. This provides a pathway toward previously unobtainable multifunctionality, extending far beyond lightweight structure applications.

Materials based on minimal surface geometries have shown superior strength and stiffness at low densities, which makes them promising continuous-based material platforms for a variety of engineering applications. In this work, it is demonstrated how these mechanical properties can be complemented by dynamic functionalities resulting from robust topological guiding of elastic waves at interfaces that are incorporated into the consid- ered material platforms. Starting from the definition of Schwarz P minimal surface, geometric parametrizations are introduced that break spatial sym- metry by forming 1D dimerized and 2D hexagonal minimal surface-based materials. Breaking of spatial symmetries produces topologically non-trivial interfaces that support the localization of vibrational modes and the robust propagation of elastic waves along pre-defined paths. These dynamic prop- erties are predicted through numerical simulations and are illustrated by performing vibration and wave propagation experiments on additively manu- factured samples. The introduction of symmetry-breaking topological inter- faces through parametrizations that modify the geometry of periodic minimal surfaces suggests a new strategy to supplement the load-bearing properties of this class of materials with novel dynamic functionalities.

Technical ceramics exhibit exceptional high-temperature properties, but unfortunately their extreme crack sensitivity and high melting point make it challenging to manufacture geometrically complex structures with sufficient strength and toughness. Emerging additive manufacturing technologies enable the fabrication of large- scale complex-shape artifacts with architected internal topology; when such topology can be arranged at the microscale, the defect population can be controlled, thus improving the strength of the material. Here, ceramic micro-architected materials are fabricated using direct ink writing (DIW) of an alumina nanoparticle-loaded ink, followed by sintering. After characterizing the rheology of the ink and extracting optimal processing parameters, the microstructure of the sintered structures is investigated to assess composition, density, grain size and defect population. Mechanical experiments reveal that woodpile architected materials with relative densities of 0.38–0.73 exhibit higher strength and damage tolerance than fully dense ceramics printed under identical conditions, an intriguing feature that can be attributed to topological toughening.

The mechanics of films undergoing volume expansion on curved substrates plays a key role in a variety of technologies including biomedical implants, thermal and environmental barrier coatings, and electrochemical energy storage systems. Silicon anodes for lithium-ion batteries are an especially challenging case because they can undergo volume variations up to 300% that results in cracking, delamination, and thus significant loss in performance. In this study, we use finite element analysis to model the volume expansion during lithiation for silicon coated on spinodal, inverse opal, gyroid, and Schwartz primitive nickel backbones and compare the distributions of maximum principal stress, strain energy density, and von Mises stress, which we use as indicators for propensity for cracking, delamination, and yielding, in order to explore the effect of backbone morphology on mechanical degradation during expansion. We show that, when compared to the inverse opal, the spinodal morphology reduces and uniformly distributes the maximum principal stress and strain energy density in the silicon layer, and delays the onset of expansion-induced yielding at all silicon layer thicknesses, which we ascribe to the unique interfacial curvature distribution of spinodal structures. This work highlights the importance of morphology on coatings undergoing volume variations and unveils the particular promise of spinodally derived materials for the design of next generation lithium-ion battery electrodes.

Widespread industrial adoption of metal additive manufacturing (AM) requires an in-depth understanding of microstructural evolution during AM. In this study, the effect of process parameters and feature thickness on the microstructures of 316L stainless steel components fabricated by laser powder bed fusion (LPBF) was examined. A standard benchmark geometry developed by the National Institute of Standards and Technology, which contained walls of 0.5, 2.5 and 5.0 mm in thickness, was used. Optical microscopy, finite element analysis, scanning electron microscopy and electron backscatter diffraction revealed dramatic microstructural differences in features of different thickness within the same component. The feature thickness influenced the cooling rate, which in turn impacted the melt pool size, solidification microstructure, grain morphology and density of geometrically necessary dislocations. The relationship between feature size and grain morphology was dependent on the energy input used during LPBF. Such behavior suggested that local manipulation of LPBF process parameters can be employed to achieve microstructural homogeneity within the as-printed stainless steel components.

Large bone fractures often require porous implants for complete healing. In this work, we numerically investigate the suitability of three topologically very different architected materials for long bone implants: the octet truss-based lattice, the Schwartz P minimal surface-based lattice and the spinodal stochastic surface-based lattice. Each implant topology (reinforcement) and its surrounding tissue (soft matrix) are modeled as a composite system via finite element analysis. Performance metrics are defined based on the Young’s modulus, the peak stress under service conditions, the interfacial surface area per unit volume and the relative bone growth rate (estimated based on the strain transferred to the soft matrix). We show that surface-based topologies are less prone to fatigue failure and may promote supe- rior bone growth than conventional truss-based designs. Spinodal surface-based architected materials have the best performance, and can be fabricated via self-assembly approaches followed by material con- version, potentially allowing scalable fabrication of implants with unit cell sizes at the micro-scale, thus dramatically amplifying surface area per unit volume and bone growth efficiency.

Two-photon polymerization direct laser writing (TPP-DLW) is one of the most versatile technologies to additively manufacture complex parts with nanoscale resolution. However, the wide range of mechanical properties that results from the chosen combination of multiple process parameters imposes an obstacle to its widespread use. Here we introduce a thermal post-curing route as an effective and simple method to increase the mechanical properties of acrylate-based TPP-DLW-derived parts by 20-250% and to largely eliminate the characteristic coupling of processing parameters, material properties and part functionality. We identify the underlying mechanism of the property enhancement as a self-initiated thermal curing reaction, which robustly facilitates the high property reproducibility that is essential for any application of TPP-DLW.

 Oxides, hydroxides, and other surface films act as impediments to metallurgical bonding during cold spray impact adhesion, raising the critical adhesion velocity and reducing the quality of the deposited coating. Using a single-particle impact imaging approach we study how altering the passivating surface oxides with exposures to various levels of heat and humidity affect the cold spray critical adhesion veloc- ity in the case of aluminum. We analyze the thickness, composition and microstructure of the passivation layers with transmission electron microscopy (TEM), X-ray photoelectron spectroscopy (XPS), and Fourier- transform infrared spectroscopy (FTIR), and correlate our observations with a direct measurement of the critical adhesion velocity for each surface treatment. We conclude that exposures to temperatures as high as 300 °C for up to 240 min in dry air, or to room-temperature with humidity levels as high as 50% for 4 days, have negligible effect on the surface oxide layers, and by extension do not affect the critical adhesion velocity. In contrast, ambient-temperature exposure to 95% relative humidity levels for 4 days increases the critical adhesion velocity by more than 125 m/s, approximately a 14% percent increase. We observe that this distinct change in critical adhesion velocity is correlated with unique changes in the passivating layer thickness, thickness uniformity, crystallinity and composition resulting from exposure to high humidity. These results speak to particle surface treatments to improve the cold spray process. 

Though beam-based lattices have dominated mechanical metamaterials for the past two decades, low structural efficiency limits their performance to fractions of the Hashin-Shtrikman and Suquet upper bounds, i.e. the theoretical stiffness and strength limits of any isotropic cellular topology, respectively. While plate-based designs are predicted to reach the upper bounds, experimental verification has remained elusive due to significant manufacturing challenges. Here, we present a new class of nanolattices, constructed from closed-cell plate-architectures. Carbon plate-nanolattices are fabricated via two-photon lithography and pyrolysis and shown to reach the Hashin-Shtrikman and Suquet upper bounds, via in situ mechanical compression, nano-computed tomography and micro-Raman spectroscopy. Demonstrating specific strengths surpassing those of bulk diamond and average performance improvements up to 639% over the best beam-nanolattices, this study provides detailed experimental evidence of plate architectures as a superior mechanical metamaterial topology.

Triply periodic minimal surfaces (TPMSs) have long been studied by mathematicians but have recently garnered significant interest from the engineering community as ideal topologies for shell-based architected materials with both mechanical and functional applications. Here, we present a TPMS generator, MiniSurf. It combines surface visualization and CAD file generation (for both finite element modeling and additive manufacturing) within one single GUI. MiniSurf presently can generate 19 built-in and one user-defined triply periodic minimal surfaces based on their level-set surface approximations. Users can fully control the periodicity and precision of the generated surfaces. We show that MiniSurf can potentially be a very useful tool in designing and fabricating architected materials.

We have quantified the adhesion forces between two-photon polymerization direct laser writing (TPP-DLW) microstructures and glass surfaces with and without an adhesion promoter. Glass surfaces treated with an acryloxy-silane agent produce adhesion forces that are almost three times larger than the forces observed with pristine glass surfaces. Determination of the substrates’ surface free energies suggests that the observed adhesion enhancement is chemical in its nature, implying that covalent bonds are formed between the polymer and the glass by means of the silane agent. The importance of this finding is demonstrated in the successful production of glassy carbon microstructures using TPP-DLW, followed by pyrolysis.

We develop a numerical methodology for the calculation of mode-I R-curves of brittle and elastoplastic lattice materials, and unveil the impact of lattice topology, relative density and constituent material behavior on the toughening response of 2D isotropic lattices. The approach is based on finite element calculations of the J-integral on a single-edge-notch- bend (SENB) specimen, with individual bars modeled as beams having a linear elastic or a power-law elasto-plastic constitutive behavior and a maximum strain-based damage model. Results for three 2D isotropic lattice topologies (triangular, hexagonal and kagome) and two constituent materials (representative of a brittle ceramic (silicon carbide) and a strain hardening elasto-plastic metal (titanium alloy)) are presented. We extract initial frac- ture toughness and R-curves for all lattices and show that (i) elastic brittle triangular lat- tices exhibit toughening (rising R-curve), and (ii) elasto-plastic triangular lattices display significant toughening, while elasto-plastic hexagonal lattices fail in a brittle manner. We show that the difference in such failure behavior can be explained by the size of the plastic zone that grows upon crack propagation, and conclude that the nature of crack propaga- tion in lattices (brittle vs ductile) depends both on the constituent material and the lattice architecture. While results are presented for 2D truss-lattices, the proposed approach can be easily applied to 3D truss and shell-lattices, as long as the crack tip lies within the empty space of a unit cell.

Hybrid micro-architected materials with unique combinations of high stiffness, high damping, and low density are presented. We demonstrate a scalable manufacturing pro- cess to fabricate hollow microlattices with a sandwich wall architecture comprising an elastomeric core and metallic skins. In this configuration, the metallic skins provide stiff- ness and strength, whereas the elastomeric core provides constrained-layer damping. This damping mechanism is effective under any strain amplitude, and at any relative den- sity, in stark contrast with the structural damping mechanism exhibited by ultralight metallic or ceramic architected materials, which requires large strain and densities lower than a fraction of a percent. We present an analytical model for stiffness and constrained-layer damping of hybrid hollow microlattices, and verify it with finite ele- ments simulations and experimental measurements. Subsequently, this model is adopted in optimal design studies to identify hybrid microlattice geometries which provide ideal combinations of high stiffness and damping and low density. Finally, a previously derived analytical model for structural damping of ultralight metallic microlattices is extended to hybrid lattices and used to show that ultralight hybrid designs are more efficient than purely metallic ones.