This study proposes a novel algorithm for generating representative volume elements which mitigate microstructural inhomogeneities in fiber-reinforced composites. The algorithm integrates void characteristics obtained from micro-computed tomography to more accurate microstructure models. Based on these models, the effects of void content, spatial distribution, and void diameter on the mechanical behavior of CF/PEEK composites are systematically evaluated using finite element analysis and experimental validation. The results reveal that void content significantly reduces transverse tensile strength and ductility, while void size further accelerates failure and enhances brittleness. In contrast, void distribution has minimal influence on the transverse mechanical response. These findings not only offer qualitative insights into void-induced damage mechanisms but also provide a theoretical basis for optimizing microstructures to enhance the mechanical performance of CF/PEEK and similar composite systems. Finally, the limitations of this study have been discussed, and directions for future research are proposed.

Lightweight, high-strength materials formed by bonding aluminum alloy (Al) and carbon-fiber-reinforced thermoplastic (CFRTP) composite materials are widely used in impact-exposed structures, leading to structural damage and reduced service life. In this study, transverse impact experiments were conducted on Al/CFRTP adhesive joints with varying impact energies (10 J, 20 J, 30 J, 40 J) on different impact surfaces (Al and CFRTP). The energy absorption rate, damage morphology, residual strength, strain evolution on the impact surface, and failure mechanisms of the joint cross-section were analyzed. The results show that using CFRTP as the impact surface can minimize damage and maintain residual tensile strength. Regardless of whether Al or CFRTP is used as the impact surface, the energy absorption rate remains around 80%, with the final impact outcome being determined by both impact damage and mechanical interlocking. This study provides a theoretical basis for the design of high-impact-resistant Al/CFRTP adhesive joints.

The mixing process of powder materials determines the final quality of industrial products. This study employs the Discrete Element Method (DEM) to numerically characterize the effects of particle shape and mixer structure on mixing performance. Using the superquadratic equation, nine types of particles with regular shape variations are constructed, and mixing models are further simulated. The feasibility of superquadratic-generated particles is validated through a classic drum calibration experiment. To investigate the intrinsic mechanisms of particle shape effects, the motion and contact behaviors of particles are quantified by the diffusion index, proportion of rotational kinetic energy, interparticle compressive force, and contact number. Meanwhile, to examine geometry effects, three supplementary mixing simulations are conducted by varying the plow angle and deactivating the choppers. The results show that Cubic particles exhibited poor mixing performance, while disk-shaped particles outperformed cylindrical ones; Increasing the plow blade inclination angle enhanced particle convection and diffusion, whereas excessively small angles may fail to achieve homogeneous mixing; The auxiliary shear of chopper blades promoted particle diffusion, effectively overcoming dead zones between plow blade intervals.