Through in situ electron backscatter diffraction (EBSD) experiments, this paper uncovers dominant damage mechanisms in traditional magnesium alloys exhibiting deformation twinning. The findings emphasize the level of deleterious strain incompatibility induced by twin interaction with other deformation modes and microstructural defects. A double fiber obtained by plane-strain extrusion as a starting texture of AM30 magnesium alloy offered the opportunity to track deformation by EBSD in neighboring grains where some undergo profuse {1 0 1 2} twinning and others do not. For a tensile loading applied along extrusion transverse (ET) direction, those experiencing profuse twinning reveal a major effect of grain boundaries on non-Schmid behavior affecting twin variant selection and growth. Similarly, a neighboring grain, with its 〈c〉-axis oriented nearly perpendicular to tensile loading, showed an abnormally early nucleation of {1 0 1 1} contraction twins (2% strain) while the same {1 0 1 1} twin mode triggering under 〈c〉-axis uniaxial compression have higher value of critical resolved shear stress exceeding the values for pyramidal 〈c + a〉 dislocations. The difference in nucleation behavior of contraction vs. compression {1 0 1 1} twins is attributed to the hydrostatic stresses that promote the required atomic shuffles at the core of twinning disconnections.

Large-format additive manufacturing (LFAM) is used to print large-scale polymer structures. Understanding the thermal and mechanical properties of polymers suitable for large-scale extrusion is needed for design and production capabilities. An in-house-built LFAM printer was used to print polyethylene terephthalate glycol with 30% carbon fiber (PETG CF30%) samples for thermomechanical characterization. Thermogravimetric analysis (TGA) shows that the samples were 30% carbon fiber by weight. X-ray microscopy (XRM) and porosity studies find 25% voids/volume for undried material and 1.63% voids/volume for dry material. Differential scanning calorimetry (DSC) shows a glass transition temperature (T_g) of 66 °C, while dynamic mechanical analysis (DMA) found T_g as 82 °C. The rheology indicated that PETG CF30% is a good printing material at 220–250 °C. Bending experiments show an average of 48.5 MPa for flexure strength, while tensile experiments found an average tensile strength of 25.0 MPa at room temperature. Comparison with 3D-printed PLA and PETG from the literature demonstrated that LFAM-printed PETG CF30% had a comparative high Young’s modulus and had similar tensile strength. For design purposes, prints from LFAM should consider both material choice and print parameters, especially when considering large layer heights.

Switchable multistable structures (SMS) are additively manufactured metamaterials. SMS are printed in polylactic acid, a shape memory polymer, and pre-strain is stored in bilayers during fused deposition modeling 3D printing process that encode different stable states can be activated above the glass transition temperature (T_g). Eight filament colors were used to 3D print sample squares. A hot water bath was used to determine sample bistability or monostability. Differential scanning calorimetry determined the T_g and melting temperature, (T_m). Thermogravimetric analysis was used to investigate colored filament thermal stability. The viscoelasticity of colored filament was investigated with melt rheology and the crystallinity of the printed samples was studied with X-ray diffraction. Filament color was an indicator of bistability and colors with lower T_m values tended to be bistable. Polyethylene terephthalate glycol SMS exhibited the shape memory effect but did not show bistability with the given print parameters. Bistability is achieved when the difference between the pre-strain of the bilayers is less than the energy needed to snap the sample to a given state. The relationship between monostability, self-snapping back to a favored state, and bistability is explained by a series of mathematical equations. Future work includes printing pre-strain relationship and the molecular level impact.

With decreasing production costs, carbon nanomaterials have become common, scalable, and cost-effective additives in high-performance composites due to the potentially significant increases in mechanical, thermal, and electrical properties. The mechanical performance of carbon nanomaterial-reinforced matrix materials under high-strain-rate compressive conditions was investigated. This study compares neat epoxy-amine with 0.1 wt.% loadings of graphene or graphite dispersed in epoxy-amine. Quasi-static and high-rate testing was conducted using an Instron load frame and Split Hopkinson Pressure Bar (SHPB), respectively, to assess the material’s response to increasing strain rates via compressive loadings. No significant change in compressive strength was observed at quasi-static strain rates, with the 0.1 wt.% graphene sample showing no significant deviation from the neat resin at high strain rates. In contrast, the 0.1 wt.% graphite sample exhibited a substantial reduction in comparative compressive strength, decreasing by ~43% at 10² s⁻¹ strain rate and ~42% at 10³ s⁻¹ strain rate. While graphene may not significantly enhance stiffness at high strain rates, its ability to preserve ductility without introducing failure-prone features makes it a more effective additive for dynamic applications.