硅酸盐学报

3D打印超高性能混凝土受压损伤断裂机理的多尺度研究

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张慧 ¹ , 武杰 ¹ , 黄宇劼 ¹ , 董彦莉 ¹ , 彭程明 ² , 武圣凯 ¹ , 徐世烺 ³

硅酸盐学报 | 研究论文 2025,53(11): 3313-3328

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硅酸盐学报 |研究论文 2025 , 53 (11) : 3313 -3328

3D打印超高性能混凝土受压损伤断裂机理的多尺度研究

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张慧¹, 武杰¹, 黄宇劼¹, 董彦莉¹, 彭程明², 武圣凯¹, 徐世烺³

作者信息

^1．中北大学环境与安全工程学院，太原 030051

^2．武汉大学土木建筑工程学院，武汉 430072

^3．浙江大学建筑工程学院，杭州 310058

通讯作者:

黄宇劼（1988—），男，博士，副教授；

董彦莉（1982—），女，博士，副教授。

作者简介:

张慧（1990—），女，博士，副教授。

Multiscale Investigation on Damage and Fracture Mechanisms of 3D Printing Ultra-High Performance Concrete under Compression

Hui ZHANG¹, Jie WU¹, Yujie HUANG¹, Yanli DONG¹, Chengmin PENG², Shengkai WU¹, Shilang XU³

Affiliations

^1.School of Environment and Safety Engineering, North University of China, Taiyuan 030051, China

^2.College of Civil Engineering and Architecture, Wuhan University, Wuhan 430072, China

^3.College of Civil Engineering and Architecture, Zhejiang University, Hangzhou 310058, China

Corresponding Author:

HUANG Yujie (1988-), male, Ph.D., Associate Professor. E-mail: mpcyujie@nuc.edu.cn;

DONG Yanli (1982-), female, Ph.D., Associate Professor. dongyli82@nuc.edu.cn

ZHANG Hui (1990-), female, Ph.D., Associate Professor. E-mail: zhangh@nuc.edu.cn

出版时间: 2025-11-20 doi: 10.14062/j.issn.0454-5648.20250260

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摘要

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近年来，建筑3D打印技术与超高性能混凝土结合（即3DP-UHPC），可同时发挥3D打印快速建造、成型可控和UHPC超高强、高韧等多重优势。已有3DP-UHPC的相关工作由于受到打印技术限制，大多针对较短钢纤维（6 mm和10 mm），而工程中UHPC常用钢纤维长度为13 mm。另外，3DP-UHPC的微细观结构特征及其引起的各向异性力学性能和损伤断裂机理的研究较为缺乏。因此，研究了13 mm钢纤维及其掺量（0、0.5%、1.0%、2.0%）对3DP-UHPC各向异性压缩力学行为的多尺度影响规律。利用数字图像相关技术（DIC）捕捉了试件裂缝的起裂、扩展和贯通等行为，开展了基于微观X射线计算断层扫描技术的微细观扫描实验，揭示了3DP-UHPC内部孔隙和纤维等特征。结果表明：3DP-UHPC的压缩破坏模式由层条间薄弱界面及孔隙主导，同时受到纤维沿打印方向的定向分布和打印工艺（条带堆叠）等因素的耦合作用，为3DP-UHPC的材料设计与工程应用提供了数据参考。

关键词

3D打印混凝土 / 超高性能混凝土 / 损伤断裂 / X射线计算断层扫描技术 / 各向异性

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Introduction

In recent years, the combination of construction 3D printing technology and ultra-high-performance concrete (3DP-UHPC) leverages the rapid construction and controllable shaping advantages of 3D printing along with the ultra-high strength and high toughness advantages of UHPC. Existing research on 3DP-UHPC, constrained by current printing technologies, has primarily focused on shorter steel fibres (6 mm and 10 mm), whereas the steel fibre length commonly used in engineering UHPC is 13 mm. Additionally, research on the micro- and meso-structural characteristics of 3DP-UHPC and the resulting anisotropic mechanical properties and damage-fracture mechanisms is relatively scarce. Therefore, revealing the multiscale effects of anisotropic compressive mechanical behaviour in 3DP-UHPC is of vital importance. This study employs 13 mm steel fibres to investigate the influence of different fibre volume fractions (0%, 0.5%, 1.0%, 2.0%) on the compressive performance of 3DP-UHPC. By combining digital image correlation technology (DIC) and X-ray computed tomography (CT) methods, we aim to clarify the coupling mechanism between fibre orientation and interlayer/interstrip interfacial defects, providing critical insights for material optimisation and engineering deployment of 3DP-UHPC.

Methods

In the experiment, 3DP-UHPC specimens with steel fibre volume fractions of 0%, 0.5%, 1.0%, and 2.0% were prepared. First, a particle packing-based mix design was carried out. By testing the particle size distribution of the raw materials and applying the modified Andreasen-Andersen model, the optimal packing proportions of the mortar matrix components were determined. Subsequently, in accordance with the GB/T 2419—2005 standard, a flow table test was conducted using an electric jolting apparatus to evaluate the printability of mixtures with varying fibre volume fractions. Furthermore, high-resolution X-CT was employed to acquire the internal structure of the specimens, from which microstructural parameters such as pore morphology and steel fibre orientation were extracted. Finally, uniaxial compression tests were performed using DIC to measure the compressive strength and to capture, in real time, the processes of crack initiation, propagation, and coalescence, thereby revealing the evolution characteristics of the failure modes. In this process, the synergistic effects between interlayer interfacial defects and fibre orientation were further analysed, and their coupling mechanisms during damage evolution were investigated, thereby providing deeper insights into the microstructural mechanisms governing the anisotropic mechanical behaviour of 3DP-UHPC.

Results and discussion

The test results indicate that in the 3DP-UHPC specimens, a total of 37 irregularly shaped large pores were observed at interlayer and interstrip interfaces, with equivalent diameters ranging from 2000 μm to 3200 μm. These accounted for only 0.174% of the total pore volume, while the remaining 92.195% consisted of nearly spherical or ellipsoidal pores, resembling the typical pore morphology of cast UHPC. Notably, the maximum (3200 μm) and average (264 μm) equivalent pore diameters in the printed specimens were both smaller than those reported for cast UHPC (4500 μm and 700 μm), suggesting that the extrusion process during printing effectively compacts the material and facilitates air removal. Therefore, the total porosity of 3DP-UHPC (2.24%) was lower than that of cast UHPC (3.45%-5.90%).

Steel fibres within 3DP-UHPC exhibit a clear tendency to align along the printing direction (x-axis), with more pronounced orientation in the x-z plane than in the x-y plane. Specifically, 65.2% of fibres were aligned at θ = 75°-90° in the x-z plane, compared to 32.8% at φ = 75°-90° in the x-y plane. This anisotropic distribution stems from the filament geometry, where the height (17 mm) is smaller than the width (36 mm), creating spatial constraints that favour alignment in the vertical cross-section. In total, 3,324 fibres (52%) were oriented within the 60°-90° range, reflecting a strong directional preference induced by the layer-by-layer deposition process.

The compressive strength of 3DP-UHPC exhibits directional anisotropy, influenced by layer interfaces, fibre volume fractions, and fibre orientation. At fibre volume fractions of 0.5%, 1.0%, and 2.0%, compressive strength consistently followed the order x < y <z, with the weakest-to-strongest directional differences being 2.95%, 7.82%, and 19.50%, respectively. These values are all below 20% and notably lower than those reported in earlier studies. The achieved reduction in anisotropy is attributed to the optimisation of printing parameters in this study, particularly adjustments to printing speed and path, which improved inter-filament contact, enhanced pore filling, and mitigated the adverse effects of interfacial defects.

3DP-UHPC outperforms cast UHPC in compressive strength across all principal directions (x, y, and z) at fibre volume fractions of 0%, 0.5%, and 1.0%. This advantage is due in part to the absence of fibre sedimentation, water bleeding, and entrapped air defects that may occur during vibration-based casting. The extrusion-based fabrication in 3D printing mitigates these issues, resulting in improved uniformity and mechanical properties. At a fibre volume fraction of 2.0%, the printed specimens exceeded cast specimens in compressive strength along the z-axis by 10%, while showing slightly lower values in the x- and y-directions.

Increasing the steel fibre volume fraction enhances the compressive strength of both 3DP and cast UHPC. For the cast specimens, an increase in fibre content from 0% to 2.0% led to a 49.9% improvement in compressive strength. In the 3DP-UHPC specimens, the same increase led to strength enhancements of 16.8%, 11.0%, and 37.7% in the x-, y-, and z-directions, respectively, indicating that the reinforcing effect of fibres is directionally dependent. Even at a modest fibre volume fraction of 0.5%, compressive strength stabilised around 133 MPa across all directions, indicating a beneficial role in mechanical consistency. In contrast, fibre-free specimens showed brittle failure dominated by interfacial defects, resulting in greater variability in strength measurements.

Conclusion

The 3D printing process significantly influences the microstructural characteristics and mechanical performance of 3DP-UHPC. Although certain interlayer and interstrip voids are inevitably introduced during the 3D printing process, the extrusion-induced "degassing" effect helps lower the overall porosity, resulting in a denser microstructure in 3DP-UHPC compared to conventionally cast UHPC. Under the combined effects of nozzle extrusion and printing path guidance, steel fibres tend to align along the printing direction, in contrast to the random distribution observed in cast specimens. This directional alignment improves the crack-bridging efficiency of fibres. The compressive failure behaviour exhibits pronounced anisotropy: under loading in the x-direction, cracks preferentially propagate along interlayer interfaces, while in the z-direction, fibre alignment enhances bridging capacity and delays crack growth. The coupled effects of fibre orientation and interfacial quality are primary contributors to this anisotropy. Enhancing the extrusion-interlocking mechanism between adjacent filaments can improve interfacial densification, thereby mitigating mechanical anisotropy. The steel fibre volume fraction also plays a critical role in both strength and stability: increasing the fibre content significantly enhances compressive strength, particularly under loading in the z-direction; in contrast, lower fibre volume fractions, although less effective in improving strength, contribute to greater performance uniformity and structural consistency. This study further elucidates the multiscale mechanisms through which 13 mm steel fibres influence compressive anisotropy in 3DP-UHPC. It identifies key microstructural features, such as pore distribution and fibre orientation, and preliminarily establishes their correlation with macroscopic mechanical behaviour, providing valuable insights for optimising the structural performance of 3DP-UHPC.

Key words

3D printing concrete / ultra-high-performance concrete / damage and fracture / X-ray computed tomography / anisotropy

引用本文

张慧, 武杰, 黄宇劼, 董彦莉, 彭程明, 武圣凯, 徐世烺. 3D打印超高性能混凝土受压损伤断裂机理的多尺度研究. 硅酸盐学报, 2025 , 53 (11) : 3313 -3328 . DOI: 10.14062/j.issn.0454-5648.20250260

Hui ZHANG, Jie WU, Yujie HUANG, Yanli DONG, Chengmin PENG, Shengkai WU, Shilang XU. Multiscale Investigation on Damage and Fracture Mechanisms of 3D Printing Ultra-High Performance Concrete under Compression[J]. Journal of the Chinese Ceramic Society, 2025 , 53 (11) : 3313 -3328 . DOI: 10.14062/j.issn.0454-5648.20250260

基金

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国家自然科学基金(52208296; 52578336)

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2025年第53卷第11期

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文章信息

doi: 10.14062/j.issn.0454-5648.20250260

接收时间：2025-04-09
首发时间：2026-10-21
出版时间：2025-11-20

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收稿日期：2025-04-09
修回日期：2025-07-11

基金

国家自然科学基金(52208296; 52578336)

作者信息

^1．中北大学环境与安全工程学院，太原 030051

^2．武汉大学土木建筑工程学院，武汉 430072

^3．浙江大学建筑工程学院，杭州 310058

通讯作者:

黄宇劼（1988—），男，博士，副教授；

董彦莉（1982—），女，博士，副教授。

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2种不同金属材料的力学参数

科 Family	属数 Number of genus	种数 Number of species	占总种数比例 Percentage of total species (%)	属 Genus	种数 Number of species	占总种数比例 Percentage of total species (%)
鹅膏菌科Amanitaceae	2	11	5.26	鹅膏菌属 Amanita	10	4.78
小菇科 Mycenaceae	2	12	5.74	丝盖伞属 Inocybe	5	2.39
多孔菌科 Polyporaceae	8	14	6.70	蜡蘑属 Laccaria	5	2.39
红菇科 Russulaceae	3	23	11.00	小皮伞属 Marasmius	6	2.87
				小菇属 Mycena	11	5.26
				光柄菇属 Pluteus	5	2.39
				红菇属 Russula	17	8.13
				栓菌属 Trametes	5	2.39

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