Process-structure-property relationships are fundamental in materials science and engineering and are key to the development of new and improved materials. Symbolic regression serves as a powerful tool for uncovering mathematical models that describe these relationships. It can automatically generate equations to predict material behaviour under specific manufacturing conditions and optimize performance characteristics such as strength and elasticity. The present work illustrates how symbolic regression can derive constitutive models that describe the behaviour of various metallic alloys during plastic deformation. Constitutive modelling is a mathematical framework for understanding the relationship between stress and strain in materials under different loading conditions. In this study, two materials (age-hardenable aluminium alloy and high-chromium martensitic steel) and two different testing methods (compression and tension) are considered to obtain the required stress-strain data. The results highlight the benefits of using symbolic regression while also discussing potential challenges.

Each element in tensioned structural networks -- such as tensegrity, architectural fabrics, or medical braces/meshes -- requires a specific tension level to achieve and maintain the desired shape, stability, and compliance. These structures are challenging to manufacture, 3D print, or assemble because flattening the network during fabrication introduces multiplicative inaccuracies in the network's final tension gradients. This study overcomes this challenge by offering a fabrication algorithm for direct 3D printing of such networks with programmed tension gradients, an approach analogous to the spinning of spiderwebs. The algorithm: (i) defines the desired network and prescribes its tension gradients using the force density method; (ii) converts the network into an unstretched counterpart by numerically optimizing vertex locations toward target element lengths and converting straight elements into arcs to resolve any remaining error; and (iii) decomposes the network into printable toolpaths; Optional additional steps are: (iv) flattening curved 2D networks or 3D networks to ensure 3D printing compatibility; and (v) automatically resolving any unwanted crossings introduced by the flattening process. The proposed method is experimentally validated using 2D unit cells of viscoelastic filaments, where accurate tension gradients are achieved with an average element strain error of less than 1.0\%. The method remains effective for networks with element minimum length and maximum stress of 5.8 mm and 7.3 MPa, respectively. The method is used to demonstrate the fabrication of three complex cases: a flat spiderweb, a curved mesh, and a tensegrity system. The programmable tension gradient algorithm can be utilized to produce compact, integrated cable networks, enabling novel applications such as moment-exerting structures in medical braces and splints.

This paper introduces a novel deep-learning approach to predict true stress-strain curves of high-strength steels from small punch test (SPT) load-displacement data. The proposed approach uses Gramian Angular Field (GAF) to transform load-displacement sequences into images, capturing spatial-temporal features and employs a Sequence-to-Sequence (Seq2Seq) model with an LSTM-based encoder-decoder architecture, enhanced by multi-head cross-attention to improved accuracy. Experimental results demonstrate that the proposed approach achieves superior prediction accuracy, with minimum and maximum mean absolute errors of 0.15 MPa and 5.58 MPa, respectively. The proposed method offers a promising alternative to traditional experimental techniques in materials science, enhancing the accuracy and efficiency of true stress-strain relationship predictions.

In this paper, we present a surrogate-based multiscale approach to model constant strain-rate and creep experiments on unidirectional thermoplastic composites under off-axis loading. In previous contributions, these experiments were modeled through a single-scale micromechanical simulation under the assumption of macroscopic homogeneity. Although efficient and accurate in many scenarios, simulations with low-off axis angles showed significant discrepancies with the experiments. It was hypothesized that the mismatch was caused by macroscopic inhomogeneity, which would require a multiscale approach to capture it. However, full-field multiscale simulations remain computationally prohibitive. To address this issue, we replace the micromodel with a Physically Recurrent Neural Network (PRNN), a surrogate model that combines data-driven components with embedded constitutive models to capture history-dependent behavior naturally. The explainability of the latent space of this network is also explored in a transfer learning strategy that requires no re-training. With the surrogate-based simulations, we confirm the hypothesis raised on the inhomogeneity of the macroscopic strain field and gain insights into the influence of adjustment of the experimental setup with oblique end-tabs. Results from the surrogate-based multiscale approach show better agreement with experiments than the single-scale micromechanical approach over a wide range of settings, although with limited accuracy on the creep experiments, where macroscopic test effects were implicitly taken into account in the material properties calibration.

Crystal plasticity (CP) modeling is a vital tool for predicting the mechanical behavior of materials, but its calibration involves numerous (>8) constitutive parameters, often requiring time-consuming trial-and-error methods. This paper proposes a robust calibration approach using Bayesian optimization (BO) to identify optimal CP model parameters under fatigue loading conditions. Utilizing cyclic data from additively manufactured Hastelloy X specimens at 500 degree-F, the BO framework, integrated with a Gaussian process surrogate model, significantly reduces the number of required simulations. A novel objective function is developed to match experimental stress-strain data across different strain amplitudes. Results demonstrate that effective CP model calibration is achieved within 75 iterations, with as few as 50 initial simulations. Sensitivity analysis reveals the influence of CP parameters at various loading points on the stress-strain curve. The results show that the stress-strain response is predominantly controlled by parameters related to yield, with increased influence from backstress parameters during compressive loading. In addition, the effect of introducing twins into the synthetic microstructure on fatigue behavior is studied, and a relationship between microstructural features and the fatigue indicator parameter is established. Results show that larger diameter grains, which exhibit a higher Schmid factor and an average misorientation of approximately 42 degrees +/- 1.67 degree, are identified as probable sites for failure. The proposed optimization framework can be applied to any material system or CP model, streamlining the calibration process and improving the predictive accuracy of such models.

Metamaterials, synthetic materials with customized properties, have emerged as a promising field due to advancements in additive manufacturing. These materials derive unique mechanical properties from their internal lattice structures, which are often composed of multiple materials that repeat geometric patterns. While traditional inverse design approaches have shown potential, they struggle to map nonlinear material behavior to multiple possible structural configurations. This paper presents a novel framework leveraging video diffusion models, a type of generative artificial Intelligence (AI), for inverse multi-material design based on nonlinear stress-strain responses. Our approach consists of two key components: (1) a fields generator using a video diffusion model to create solution fields based on target nonlinear stress-strain responses, and (2) a structure identifier employing two UNet models to determine the corresponding multi-material 2D design. By incorporating multiple materials, plasticity, and large deformation, our innovative design method allows for enhanced control over the highly nonlinear mechanical behavior of metamaterials commonly seen in real-world applications. It offers a promising solution for generating next-generation metamaterials with finely tuned mechanical characteristics.

We use a space-time discretization based on physics informed deep learning (PIDL) to approximate solutions of a class of rate-dependent strain gradient plasticity models. The differential equation governing the plastic flow, the so-called microforce balance for this class of yield-free plasticity models, is very stiff, often leading to numerical corruption and a consequent lack of accuracy or convergence by finite element (FE) methods. Indeed, setting up the discretized framework, especially with an elaborate meshing around the propagating plastic bands whose locations are often unknown a-priori, also scales up the computational effort significantly. Taking inspiration from physics informed neural networks, we modify the loss function of a PIDL model in several novel ways to account for the balance laws, either through energetics or via the resulting PDEs once a variational scheme is applied, and the constitutive equations. The initial and the boundary conditions may either be imposed strictly by encoding them within the PIDL architecture, or enforced weakly as a part of the loss function. The flexibility in the implementation of a PIDL technique often makes for its ready interface with powerful optimization schemes, and this in turn provides for many possibilities in posing the problem. We have used freely available open-source libraries that perform fast, parallel computations on GPUs. Using numerical illustrations, we demonstrate how PIDL methods could address the computational challenges posed by strain gradient plasticity models. Also, PIDL methods offer abundant potentialities, vis-\'a-vis a somewhat straitjacketed and poorer approximant of FE methods, in customizing the formulation as per the problem objective.

Simulating the mechanical response of advanced materials can be done more accurately using concurrent multiscale models than with single-scale simulations. However, the computational costs stand in the way of the practical application of this approach. The costs originate from microscale Finite Element (FE) models that must be solved at every macroscopic integration point. A plethora of surrogate modeling strategies attempt to alleviate this cost by learning to predict macroscopic stresses from macroscopic strains, completely replacing the microscale models. In this work, we introduce an alternative surrogate modeling strategy that allows for keeping the multiscale nature of the problem, allowing it to be used interchangeably with an FE solver for any time step. Our surrogate provides all microscopic quantities, which are then homogenized to obtain macroscopic quantities of interest. We achieve this for an elasto-plastic material by predicting full-field microscopic strains using a graph neural network (GNN) while retaining the microscopic constitutive material model to obtain the stresses. This hybrid data-physics graph-based approach avoids the high dimensionality originating from predicting full-field responses while allowing non-locality to arise. By training the GNN on a variety of meshes, it learns to generalize to unseen meshes, allowing a single model to be used for a range of microstructures. The embedded microscopic constitutive model in the GNN implicitly tracks history-dependent variables and leads to improved accuracy. We demonstrate for several challenging scenarios that the surrogate can predict complex macroscopic stress-strain paths. As the computation time of our method scales favorably with the number of elements in the microstructure compared to the FE method, our method can significantly accelerate FE2 simulations.

Stress-strain curves, or more generally, stress functions, are an extremely important characterization of a material's mechanical properties. However, stress functions are often difficult to derive and are narrowly tailored to a specific material. Further, large deformations, high strain-rates, temperature sensitivity, and effect of material parameters compound modeling challenges. We propose a generalized deep neural network approach to model stress as a state function with quantile regression to capture uncertainty. We extend these models to uniaxial impact mechanics using stochastic differential equations to demonstrate a use case and provide a framework for implementing this uncertainty-aware stress function. We provide experiments benchmarking our approach against leading constitutive, machine learning, and transfer learning approaches to stress and impact mechanics modeling on publicly available and newly presented data sets. We also provide a framework to optimize material parameters given multiple competing impact scenarios.

Machine learning (ML) is emerging as a transformative tool for the design of architected materials, offering properties that far surpass those achievable through lab-based trial-and-error methods. However, a major challenge in current inverse design strategies is their reliance on extensive computational and/or experimental datasets, which becomes particularly problematic for designing micro-scale stochastic architected materials that exhibit nonlinear mechanical behaviors. Here, we introduce a new end-to-end scientific ML framework, leveraging deep neural operators (DeepONet), to directly learn the relationship between the complete microstructure and mechanical response of architected metamaterials from sparse but high-quality in situ experimental data. The approach facilitates the inverse design of structures tailored to specific nonlinear mechanical behaviors. Results obtained from spinodal microstructures, printed using two-photon lithography, reveal that the prediction error for mechanical responses is within a range of 5 - 10%. Our work underscores that by employing neural operators with advanced micro-mechanics experimental techniques, the design of complex micro-architected materials with desired properties becomes feasible, even in scenarios constrained by data scarcity. Our work marks a significant advancement in the field of materials-by-design, potentially heralding a new era in the discovery and development of next-generation metamaterials with unparalleled mechanical characteristics derived directly from experimental insights.