Data-Driven Plasticity Modeling via Acoustic Profiling

Predicting the stress-strain behaviors of additively manufactured materials is crucial for part qualification in additive manufacturing (AM). Conventional physics-based constitutive models often oversimplify material properties, while data-driven machine learning (ML) models often lack physical consistency and interpretability. To address these issues, we propose a physics-informed machine learning (PIML) framework to improve the predictive performance and physical consistency for predicting the stress-strain curves of additively manufactured polymers and metals. A polynomial regression model is used to predict the yield point from AM process parameters, then stress-strain curves are segmented into elastic and plastic regions. Two long short-term memory (LSTM) models are trained to predict two regions separately. For the elastic region, Hooke's law is embedded into the LSTM model for both polymer and metal. For the plastic region, Voce hardening law and Hollomon's law are embedded into the LSTM model for polymer and metal, respectively. The loss-based and activation-based PIML architectures are developed by embedding the physical laws into the loss and activation functions, respectively. The performance of the two PIML architectures are compared with two LSTM-based ML models, three additional ML models, and a physics-based constitutive model. These models are built on experimental data collected from two additively manufactured polymers (i.e., Nylon and carbon fiber-acrylonitrile butadiene styrene) and two additively manufactured metals (i.e., AlSi10Mg and Ti6Al4V). Experimental results demonstrate that two PIML architectures consistently outperform the other models. The segmental predictive model with activation-based PIML architecture achieves the lowest MAPE of 10.46+/-0.81% and the highest R^2 of 0.82+/-0.05 arocss four datasets.

We present a soft corrugated tube sensor designed to estimate strain in each half segment. When air flows through the tube, the internal corrugated cavities induce pressure oscillations that excite the tube's standing wave resonance mode, generating an acoustic tone. Stretching the tube affects both the resonance mode frequency, due to changes in overall length, and the frequency-flow speed relationship, due to variations in cavity width, which is particularly useful for local strain estimation. By sweeping flow rates in a controlled manner, we collected resonance frequency data across flow speeds under various local stretch conditions, enabling a machine learning algorithm (gradient boosting regressor) to estimate segmental strain with high accuracy. The dual-period tube design (3.1 mm and 4.18 mm corrugation periods) achieved a mean absolute error (MAE) of 0.8 mm, while the single-period tube (3.1 mm) provided a satisfactory MAE of 1 mm. Testing on a mannequin finger demonstrated the sensor's capability to differentiate multi-joint configurations, showing its potential for estimating non-uniform deformations in soft bodies.

Crystal plasticity (CP) simulations predict the mechanical behavior of polycrystalline metals, yet their routine use is hindered by the manual effort of configuring heterogeneous tools, orchestrating multi-step data pipelines, and calibrating constitutive parameters against experiments. These bottlenecks impede productivity in systematic parameter studies, motivating interest in automated workflows. This study presents CP-Agent, a harness-engineered LLM-based agent that autonomously executes complete CP modeling workflows from natural-language tasks. Operating under the ReAct paradigm, the agent reasons about tool selection and sequencing while delegating numerical search to established optimizers. The harness comprises a minimal system prompt, typed tool definitions, a dispatcher, and a safety-bounded iteration loop, encoding domain knowledge through tool schemas rather than hard-coded logic. CP-Agent is demonstrated on four case studies: calibrating four slip parameters of additively manufactured stainless steel 316L against tensile data; validating the workflow against published copper benchmarks, reproducing stress-strain and texture evolution; recovering the initial crystallographic texture of copper, where the agent correctly identifies a diffuse initial texture; and reproducing the multi-pass rolling texture evolution of a Mg-Zn-Ca alloy, where the agent chains five deformation passes and recovers the experimentally observed weakened, split basal texture. In all cases, the agent inferred the correct execution sequence from the task statement, robustly across repeated runs, and delivered physically interpretable results. This work establishes harness engineering as a systematic approach to automating CP modeling workflows while maintaining physical interpretability and auditability through visible reasoning traces.