This presentation reviews new developments for materials characterization for constitutive and failure modeling, focusing on
1) Smart factory research on material characterization process,
2) Gradient properties characterization,
3) Laminated aluminum pouch composite film properties.

First, smart factory research can be achievable through hardware automation and DIC technology. The capability is demonstrated with a new constructed automatic testing and calibration system.

Second, aluminum-steel resistance spot welding (Al-steel RSW) is considered. This study develops an inhomogeneous sample to extract the material properties for the fusion zone (FZ), heat-affected zone (HAZ), and intermetallic compound (IMC) layers with a single tensile test. Fracture mechanisms of Al-steel RSW are examined using a miniature weld performance test and in-situ micro DIC.

Finally, lithium-ion battery pouch film is composed of polypropylene, aluminum, PET, and nylon. The material properties of the four layers are characterized by the delamination behavior between the aluminum and polymer layers during tensile testing and the polymer properties through nano-indentation testing. Individual layer properties are optimized to satisfy the combined stress-strain curve. The modelled properties were verified through wrinkling and forming behaviors.

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