Carbonaceous slate is one kind of metamorphic rocks with developed foliation, which is frequently encountered during tunnel construction in Western China. The foliation plays a crucial role in the stability of tunnels. For this, we conducted uniaxial compression tests, acoustic emission (AE) monitoring and scanning electron microscope (SEM) tests on carbonaceous slate. The results show that the strength, failure mode, and AE characteristics exhibit marked anisotropy with the angle between the axial and the foliation (beta). As beta increases, the ultrasonic wave velocity decreases monotonically, whereas the uniaxial compressive strength (UCS) displays a distinctive U-shaped trend. The elastic modulus initially decreases and then increases. The cumulative AE counts curve and energy curve show a stepped growth when beta 45 degrees. Upon failure, the energy release accounts for the highest proportion (67%) when beta = 45 degrees, while the proportions in other cases are less than 37%. The maximum percentage (31%) of shear cracks is reported when beta = 60 degrees, which is six times greater than that at beta = 0 degrees. Moreover, Kernel density estimation analysis reveals that the high concentration area with low AF (AE counts/duration time) and high RA (rise time/amplitude) increases initially, and then decreases when beta > 60 degrees. In addition, nine types of cracks and seven modes of failure were identified. The foliation angle has a pronounced impact on shear failure modes in comparison with tensile failure modes. The supports could suffer larger deformation when beta >= 60 degrees compared to other cases. The failure behaviors correspond well with field observations. (c) 2025 Institute of Rock and Soil Mechanics, Chinese Academy of Sciences. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/ 4.0/).

The SLS additive manufacturing industry enables the development of products for diverse applications with distinct properties due to its excellent surface finish and ability to create varied part geometries, but it consumes high-performance materials with high acquisition costs. An extensive quarrying of stone leads to the accumulation of mineral residues, posing environmental hazards by contaminating soil and water when disposed of in landfills. The primary objective of the study was to incorporate mineral waste into the SLS technique and investigate the influence of its addition, along with a silane-based chemical treatment, on the mechanical performance of polymer-mineral composites (PA12-slate). Additionally, the feasibility of producing a highly loaded printed prototype, employing 50 wt% of mineral waste, was examined. Samples of PA12, PA12 blended with 50 wt% slate waste, and slate waste treated with silane underwent fabrication via selective laser sintering (SLS) and subsequent mechanical characterization, including tensile, flexural, and compressive tests. Additionally, the samples underwent accelerated aging using a QUV weathering tester, followed by mechanical characterization. The geometric accuracy, stability, and processing feasibility of these formulations were evaluated through SLS-printed composite prototypes utilizing PA12_50Sla_Si. It was found that the addition of 50% of slate to the PA12 presented mechanical properties decreasing compared to the printed PA12 only. However, an increase was verified when using silane-induced mineral bonding. The incorporation of mineral agents and silane enhanced the resistance of PA12 to aging. However, after aging, both tensile and flexural strength decreased across all printed samples. Nonetheless, this study showcased the feasibility of producing complex PA12-slate waste specimens containing up to 50 wt% of mineral waste using the SLS printing technique. Therefore, SLS presents itself as a viable means of adding value to this mineral waste.