Thermo-mechanical toner transfer for high-quality digital image correlation speckle patterns

• A novel toner-transfer technique to impress well-defined patterns is introduced.
• The technique is suitable for metallic and cement composite specimens.
• The technique is suitable for flat and curved surfaces.
• Proof of concept is demonstrated through experiments on steel and aluminum samples.
• Pattern degradation under temperatures past the toner melting point is negligible.

The accuracy and spatial resolution of full-field deformation measurements performed through digital image correlation are greatly affected by the frequency content of the speckle pattern, which can be effectively controlled using particles with well-defined and consistent shape, size and spacing. This paper introduces a novel toner-transfer technique to impress a well-defined and repeatable speckle pattern on plane and curved surfaces of metallic and cement composite specimens. The speckle pattern is numerically designed, printed on paper using a standard laser printer, and transferred onto the measurement surface via a thermo-mechanical process. The tuning procedure to compensate for the difference between designed and toner-transferred actual speckle size is presented. Based on this evidence, the applicability of the technique is discussed with respect to surface material, dimensions and geometry. Proof of concept of the proposed toner-transfer technique is then demonstrated for the case of a quenched and partitioned welded steel plate subjected to uniaxial tensile loading, and for an aluminum plate exposed to temperatures up to 70% of the melting point of aluminum and past the melting point of typical printer toner powder.