This study investigates the fracture behavior of bimaterials, specifically focusing on the Alumina/Silver interface under mechanical, thermal, and thermo-mechanical loading conditions. Through the analysis of Stress Intensity Factors (SIFs) across various crack lengths, temperatures, and along multiple regions and fronts of the crack, we provide valuable insights into the distribution and the nature of stresses, shedding light on how different loading conditions influence crack propagation. Our findings show that, under mechanical loading, the tensile mode SIF (KI) exhibits a straightforward relationship with applied stress, increasing with crack length. In contrast, under thermal loading, KI generally decreases on the surface as the temperature rises, while it increases within the interface, highlighting the complex interplay of thermal expansion and the mismatch of material properties. The thermo-mechanical case combines these effects, further amplifying the role of residual stresses from manufacturing processes and thermal stresses, significantly affecting SIFs and crack growth, especially in bimaterial interfaces. These results contribute to a deeper understanding of fracture mechanisms in hybrid materials.

Many industries rely heavily on the availability and reliability of complex structural and functional components to execute operations efficiently. However, failure of components during service occurs due to exposure to unfavourable operating conditions, causing wear and tear of these components. The damage will result in costly downtime and potential safety hazards. Repairing, remanufacturing and refurbishing these complex parts is critical. Restoring broken structures into operation ensures the smooth operation of the industry, thus preventing losses. Conventionally, repairing parts poses a challenge. However, Wire-arc additive manufacturing (WAAM), which employs the welding principle, has revolutionised component repairing or remanufacturing. This paper reviews the literature on manufacturing complex parts, repair, remanufacture and refurbishment of broken structural and functional parts using WAAM technology. This paper also highlights the various strategies and techniques currently used to improve the quality of WAAM 3D printed parts. The study further covers the immense potential of WAAM in revolutionising the remanufacturing and repair of components. The review study has provided a roadmap for future research and development to take full advantage of this new cutting-edge manufacturing technology.

This paper presents a numerical investigation on the flexural performance of a novel cementitious reinforced GEM-TECH material using finite element method. A discrete nonlinear FE model using the commercial software ANSYS was employed to model a steel-reinforced GEM-TECH beam. Element SOLID65 was used to model the cementitious material while LINK180 element was used to model the reinforcing bars and stirrups. For model validation, FEA results and crack plots were compared to those obtained from the experimental results of five reinforced GEM-TECH beams: three beams designed with target density of 1810 kg/m3 and two beams with target density of 1600 kg/m3. Both load-deflection plots and the failure mode crack plots predicted by the FE model were in good agreement with the experimental results.