In this paper, the tensile behavior of unidirectional carbon/epoxy prepreg is experimentally analyzed at varying loads and temperatures, focusing on the considerable nonlinearity at the beginning of the stress-strain curve. The high viscosity of this material presented difficulties in securely holding specimens during tensile testing. As a result, modifications were made to the conventional gripping method to enable the acquisition of reliable test data. Additionally, a longer gauge length was chosen to minimize the impact of slippage on the elastic modulus measurement. To support the experiment, a micromechanical model of a prepreg tow with fiber waviness is proposed. An RVE model of periodically distributed unidirectional waved cylindrical fibers embedded within the matrix is developed to predict the effective material stiffness parameters. Numerical results are presented for different amplitude-to-wavelength ratios which indicate the fiber waviness reduces the tensile modulus of the composite. The simulation results are in good agreement with the uniaxial tensile test of the prepreg tow.

This paper is the second part of a two-part report studying the responses of a typical point-contact elastohydrodynamic lubrication (EHL) problem to multiscale roughness that is mimicked by artificially generated waviness with different amplitudes, frequencies, and directions. The previous Part I paper (doi:10.3390/lubricants10120368) focuses on the full film regime, while the current paper focuses on the partial film regime. The amplitudes and frequencies are related to the feature geometry of smooth EHL problems. Generated waviness is input to a transient thermal EHL model. The simulation is conducted 1,600 times for different waviness parameters, loads, and speeds. Eight performance parameters are extracted: the asperity contact ratio, minimum film thickness, maximum pressure, central point film thickness, central point pressure, mean film thickness, coefficient of friction (COF), and the maximum temperature rise. The ratios of the first seven parameters with and without waviness and the asperity contact ratio values are plotted on the frequency–amplitude coordinate plane as contour maps. The influences of the amplitude, frequency, wave direction, load, and speed on the eight performance parameters are analyzed and summarized. The simulated data and plotted contour maps are provided to the readers in the Supplementary Material.

This paper reports the effect of as-deposited surface condition on the fatigue strength in an additive manufactured titanium alloy Ti-6Al-4V (WAAM Ti64). First, local stress concentration caused by the surface waviness was quantified by a metrology technique followed by numerical modelling. Fatigue tests were conducted under bending load with the as-deposited surface being under tensile cyclic stress. The applicability of two predictive methods was studied and compared with the fatigue test results. The traditional notch stress method overestimated the fatigue strength by a factor of 1.5 at a given life; the poor agreement with the test is attributed to the crack propagation from the waviness being dominant in the bending test, i.e., the crack initiation stage was short, hence the local stress method is unsuitable. The fracture mechanics approach has delivered good predictions at every applied stress levels. The method treats a waviness trough as an initial crack. This approach is suitable for predicting the fatigue life in materials built by wire based directed energy deposition processes.

The present work proposes a novel manufacturing technique based on the combination of Laser Metal Deposition, Laser Beam Machining and Laser Polishing processes for the complete manufacturing of complex parts. Therefore, the complete process is based on the application of a laser heat source both for the building of the preform shape of the part by additive manufacturing and for the finishing operations. Their combination enables to manufacture near-net-shape parts and afterwards, remove the excess material via laser machining, which has resulted to be capable of eliminating the waviness resulting from the additive process. Besides, surface quality is improved via laser polishing to reduce the roughness of the final part. Therefore, conventional machining operations are eliminated, what results in a much cleaner process. In order to validate the capability of this new approach, the dimensional accuracy and surface quality of the resulting parts are evaluated. The process has been validated on an Inconel 718 test part, where a previously additively built up part has been finished by means of laser machining and laser polishing.