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<p>Complex defect structures such as cavities and cracks in engineering rock masses directly determine their mechanical properties and failure modes, thereby significantly affecting the stability of surrounding rock structures. Conventional fabrication techniques struggle to replicate such complexities, limiting the applicability of laboratory test results in practical engineering. Sand powder 3D printing based on Binder Jetting Technology (BJT) offers structural controllability and stable mechanical performance, yet the low compressive strength of analogs restricts their geomechanical applications. A hybrid strengthening method combining particle gradation optimization and glass fiber reinforcement is proposed to address this limitation. The effects of binder saturation, gradation ratio, and fiber content on the mechanical properties and microstructural characteristics of analogs were systematically investigated through uniaxial compression testing, acoustic emission monitoring (AE), and scanning electron microscopy (SEM). The primary conclusions that emerged from this research are as follows: (1) binder saturation was identified as a predominant factor contributing to the strengthening of mechanical properties, independent of extraneous variables; (2) a composite ‘particle–fiber cluster complex’ is formed under sufficient binder coverage. This results in dual crack-resistance mechanisms, including energy dissipation for particle-binder interface debonding and fiber bridging confinement; (3) the maximum Uniaxial Compressive Strength (UCS) of the hybrid strengthened rock analogs reached 42.55&#xa0;MPa, representing a 174.69% increase compared to conventional rock analogs and a 23.80% increase compared to single-factor strengthened rock analogs; (4) compared with individual-factor reinforcement, the hybrid method achieved significant enhancements in mechanical performance and accurately replicated the brittle–ductile transition and strength–stiffness correlation of natural rocks. This hybrid strengthening method provides an effective and scalable pathway for fabricating high-fidelity rock analogs, offering substantial potential for physical modeling in geotechnical applications.</p>

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Hybrid Strengthening Method and Mechanism of Sand Powder 3D Printed Rock Analog

  • 期刊论文

  • 发表日期：

    2026年1月29日

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  • Xiaohan Peng,
  • Lishuai Jiang,
  • Zhe Zhang,
  • Qi Wu,
  • Haozhe Li,
  • Xuepeng Zhang

摘要

Complex defect structures such as cavities and cracks in engineering rock masses directly determine their mechanical properties and failure modes, thereby significantly affecting the stability of surrounding rock structures. Conventional fabrication techniques struggle to replicate such complexities, limiting the applicability of laboratory test results in practical engineering. Sand powder 3D printing based on Binder Jetting Technology (BJT) offers structural controllability and stable mechanical performance, yet the low compressive strength of analogs restricts their geomechanical applications. A hybrid strengthening method combining particle gradation optimization and glass fiber reinforcement is proposed to address this limitation. The effects of binder saturation, gradation ratio, and fiber content on the mechanical properties and microstructural characteristics of analogs were systematically investigated through uniaxial compression testing, acoustic emission monitoring (AE), and scanning electron microscopy (SEM). The primary conclusions that emerged from this research are as follows: (1) binder saturation was identified as a predominant factor contributing to the strengthening of mechanical properties, independent of extraneous variables; (2) a composite ‘particle–fiber cluster complex’ is formed under sufficient binder coverage. This results in dual crack-resistance mechanisms, including energy dissipation for particle-binder interface debonding and fiber bridging confinement; (3) the maximum Uniaxial Compressive Strength (UCS) of the hybrid strengthened rock analogs reached 42.55 MPa, representing a 174.69% increase compared to conventional rock analogs and a 23.80% increase compared to single-factor strengthened rock analogs; (4) compared with individual-factor reinforcement, the hybrid method achieved significant enhancements in mechanical performance and accurately replicated the brittle–ductile transition and strength–stiffness correlation of natural rocks. This hybrid strengthening method provides an effective and scalable pathway for fabricating high-fidelity rock analogs, offering substantial potential for physical modeling in geotechnical applications.