Polyvinyl alcohol (PVA) hydrogels find applications in various fields, including machinery and tissue engineering, owing to their exceptional mechanical properties. However, the mechanical properties of PVA hydrogels are subject to alteration due to environmental factors such as temperature, affecting their prolonged utilization. To enhance their lifespan, it is crucial to investigate their aging mechanisms. Using physically cross-linked PVA hydrogels, this study involved high-temperature accelerated aging tests at 60 °C for 80 d and their performance was analyzed through macroscopic mechanics, microscopic morphology, and microanalysis tests. The findings revealed three aging stages, namely, a reduction in free water, a reduction in bound water, and the depletion of bound water, corresponding to volume shrinkage, decreased elongation, and a “tough-brittle” transition. The microscopic aging mechanism was influenced by intermolecular chain spacing, intermolecular hydrogen bonds, and the plasticizing effect of water. In particular, the loss of bound water predominantly affected the lifespan of PVA hydrogel structural components. These findings provide a reference for assessing and improving the lifespan of PVA hydrogels.

This study focuses on optimizing cruciform specimen configurations for the biaxial tensile testing of soft composite materials used in the aerospace industry under conditions of large deformation. A comprehensive evaluation system based on stress–strain uniformity and load transfer efficiency was established, and the stability of these metrics during the tensile process was analyzed. Using finite element simulation and multi-parameter analysis, the main parameter set affecting specimen performance was identified. The influence of different parameters on stress–strain uniformity and load transfer efficiency was investigated. Based on the optimization criteria, an optimized planar cross-shaped specimen configuration was developed. This configuration demonstrated excellent performance stability during deformation, with final stress uniformity error controlled to within 2.2%. The final strain uniformity error was maintained at 2.9%. The fluctuation range of load transfer efficiency did not exceed 1.5%. This study provides guidelines for designing specimens for large deformation testing of soft composite materials and can be used as a reference for future work on optimizing specimens.