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Superelastic interlocking metasurfaces enabled by additive manufacturing
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DOI：10.1016/j.mattod.2026.103369.png)
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Abstract
En 中文
This work presents interlocking metasurfaces (ILMs) fabricated from superelastic materials, enabling unit-cell designs that require assembly and disassembly strains exceeding the elastic strains typical in conventional metals. The successful design, fabrication, and testing of a Tube-Lock (T-L) ILM mechanism was demonstrated. Fabricated using laser powder bed fusion (L-PBF) additive manufacturing (AM) with Ni-rich NiTi shape memory alloys (SMAs), the T-L ILM features a unique snap-fit design, achieving relatively good cyclic stability and load-bearing performance, enabling reversible engagement and disengagement. Crystallographic texture control was achieved by optimizing process parameters and scan strategies, while minimizing oxygen pick-up levels to enhance superelasticity. Finite Element Analysis (FEA) guided the geometric design, ensuring localized strain remained within a conservative 3 % for full recoverability. Experimental validation revealed excellent agreement between FEA predictions, Digital Image Correlation (DIC) strain maps, and the locking force, highlighting the model's reliability in capturing mechanical behavior. Isothermal monotonic testing of the AM-fabricated samples demonstrated near-complete strain recovery during load cycling. This work establishes a robust framework for designing durable superelastic SMA ILMs for adaptive structures and load-intensive applications.
Keywords:
Interlocking metasurfaces
Additive manufacturing
Laser-powder bed fusion
NiTi
Shape memory alloys
Superelasticity
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22
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279
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