Correlations for the pressure drop for flow through metal foam

Steady-state unidirectional pressure-drop measurements for incompressible airflow through nine open-cell aluminum foam samples, having different porosities and pore densities, were undertaken. The pressure drop increased with increasing Darcian velocity following the quadratic Forchheimer equation. The lower-porosity foam produced significantly higher pressure drop. Both the permeability and the form drag coefficient correlated well with the porosity. The correlations predicted the results of some previous studies reasonably well, especially for the low-pore-density foam.     

Equivalent particle diameter and length scale for pressure drop in porous metals

The internal architecture of metal foam is significantly different from that of traditional porous media. This provides a set of challenges for understanding the fluid flow in this relatively new class of materials. This paper proposes that despite the geometrical differences between metal foam and traditional porous media, the Ergun correlation is a good fit for the linear pressure drop as a function of the Darcian velocity, provided that an appropriate equivalent particle diameter is used. The paper investigates an appropriate particle diameter considering the physics of energy dissipation, i.e. the viscous shear and the form drag. The above approach is supported by wind tunnel steady-state unidirectional pressure drop measurements for airflow through several isotropic open-cell aluminum foam samples having different porosities and pore densities. For each foam sample, the equivalent particle diameter correlated well with the surface area per unit volume of the foam. This was also very well valid for previous porous metal pressure drop data in the open literature.     

Drag difference between steady and shocked gas flows passing through a porous body

Experimental and numerical investigations of gas flows through porous materials have been carried out. We have investigated steady and unsteady processes occurring when the gas flow interacts with porous materials. Densities and porosities of the four open-cell-type polyurethane foams which were investigated are kg/m and , with the foams having different structures. Experiments were conducted to determine the steady drag coefficient of the porous material at low Reynolds numbers, evaluated from the pressure drop. The Forchheimer equation was applied to determine the drag. Values of permeability coefficients () in the Forchheimer equation were estimated by comparing computed and experimental results. Results show that the drag coefficient is largely affected by the internal structure of the foam, and has almost no effect on the stress history, while the value of dominates the stress history variation. Differences of 1000 times exist between the steady flow and unsteady shock tube flow values. Received 15 May 1998/ Accepted 15 March 1999     

Predicting pressure drop in open-cell foams by adopting Forchheimer number

Interconnected struts arranged in 3-D foam structures pose a challenge in understanding fluid flow, which is significantly different from that in traditional porous media. Different flow regimes (Darcy, transition and weak inertia regimes) and thus, different flow laws in open-cell foams are used. The impact of characteristic lengths’ choices based on both, morphological and hydraulic parameters on flow law formulation has been studied. Ambiguities in definitions and measurements of several key parameters have been shown and limitations in the use of some parameters have been pointed out.An equivalent Reynolds number in the form of Forchheimer number (F_o) has been proposed to establish the friction factor relationship in order to avoid any morphological ambiguities. This number takes into account hydraulic characteristics of viscous and inertia regimes simultaneously. It has been observed that when F_o < 0.1, the flow through open-cell foams remains in the Darcy regime while the occurrence of weak inertia regime dominates when F_o > 1. Transition regime occurs in a narrow range of flow velocity when 0.1 < F_o < 1. The limits of transition for regime identification are found to be independent of foam morphologies. The form drag coefficient varies in relation with foam morphological parameters and is not a “universal” constant.Empirical correlations have been derived to predict hydraulic characteristics and friction factor data for different strut shapes and porosities. An excellent agreement has been obtained between predicted and numerical/experimental flow data.     

Permeability of open-cell foams under compressive strain

A model for the behavior of low-density, open-cell foam under compressive strain is proposed. Using this model, a tractable relationship between the normalized permeability and the applied strain is developed. An experimental study of the effect of strain on the permeability of open-cell polyurethane foams is presented. The experiments are performed using a Newtonian fluid in the fully laminar regime, where viscous forces are assumed to dominate. The model is found to describe the experimental data well and be independent of the foam cell size, the direction of flow with respect to the foam rise direction, and the properties of the saturating fluid. In a companion paper, the model for the permeability of open-cell foam is combined with Darcy’s law to give the contribution of viscous fluid flow to the stress–strain response of a reticulated foam under dynamic loading.     

A Theoretical Model with Experimental Verification to Predict Hydrodynamics of Foams

An experimentally validated theoretical model, based on hydraulic resistance network and scale analysis at the pore level, is developed to predict the pressure drop for flow through foams. The complex microstructure of the foams is modeled as a matrix of interconnected solid ligaments forming simple cubic arrays of cylinders. New correlations for permeability and form drag (inertia) coefficient are presented as functions of the mean pore and ligament diameter as well as the foam porosity. The present model makes it possible to conduct parametric studies. Results obtained from the proposed model are successfully compared with our experimental data as well those found in the literature to observe good agreement.     

Hydrodynamic Characterization of Nickel Metal Foam,Part 2: Effects of Pore Structure and Permeability

In this article, the structural characterization of chemical vapor deposition (CVD) nickel metal foam is presented. Scanning electron microscope and post image processing were used to carefully analyze the surface of the nickel metal foams. Data on foam unit cell, ligament thickness, projected pore diameter, and averaged porosity was obtained. Unit cell and projected pore diameters of CVD nickel metal foam possess Gaussian-like distribution. Characteristics of pore structure and its effect on permeability in Darcian flow regime were analyzed. The relations between the permeability, pore size, and porosity are presented. Present and previous data are compared with these relations. Measurement results indicate that the permeability or the viscous conductivity of the CVD processed metal foam is affected not only by the pore size, and porosity but also by the ligament structure.     

通孔泡沫铝的动态压缩行为

在SHPB装置上对渗流法制备的通孔泡沫铝进行了动态压缩实验,研究了相对密度为0.341~0.419的通孔泡沫铝在10-3~2000 s-1应变率范围内的压缩响应特征和应变率相关性,并用扫描电镜（scanning electron microscope,SEM)分析了泡沫铝的压缩变形特征。实验结果表明,通孔泡沫铝有明显应变率效应,随应变率上升,泡沫铝流动应力提高。SEM观察结果揭示,在动态压缩下,通孔泡沫铝宏观上均匀变形,微观变形机制以泡孔横向伸展坍塌为主。     

The interaction between shock waves and foam in a shock tube

An experimental study and a numerical simulation were conducted to investigate the mechanical and thermodynamic processes involved in the interaction between shock waves and low density foam. The experiment was done in a stainless shock tube (80 mm in inner diameter, 10 mm in wall thickness and 5 360 mm in length). The velocities of the incident and reflected compression waves in the foam were measured by using piezo-ceramic pressure sensors. The end-wall peak pressure behind the reflected wave in the foam was measured by using a crystal piezoelectric sensor. It is suggested that the high end-wall pressure may be caused by a rapid contact between the foam and the end-wall surface. Both open-cell and closed-cell foams with different length and density were tested. Through comparing the numerical and experimental end-wall pressure, the permeability coefficients α and β are quantitatively determined.     

Simulation of Entry-Region Flow in Open-Cell Metal Foam and Experimental Validation

Open-cell metal foam is distinguished from traditional porous media by its very high porosities (often greater than 90 %), and its web-like open structure and good permeability. As such, the foam is a very attractive core for many engineered systems, e.g., heat exchangers, filtration devices, catalysts, and reactors. The flow field inside the foam is rather complex due to flow reversal and vigorous mixing. This complexity is increased by the possible presence of an entry region. The entrance region in metal foam is usually underestimated and ignored, just like its counterpart in traditional porous media. In this paper, the actual entry length is determined by simulation and direct experiment on commercial open-cell aluminum foam. It is shown to be dependent on flow velocity and to reach a constant value for higher velocities. The complex and intrinsically random architecture of the foam is idealized using a unit geometrical model, in order to numerically investigate the flow field and pressure drop inside the foam. The Navier–Stokes equations are solved directly, and velocity and pressure fields are obtained for various approach velocities using a commercial numerical package. The entry length is ascertained from the behavior of the velocity field close to the entrance. Comparisons to experimental data were also carried out. The commercial foam that was used in the experiment had 10 ppi and porosity of 91.2 %. Air was forced to flow inside the foam using an open-loop wind tunnel. Good qualitative agreement between the modeling and experimental results are obtained. The agreement lends confidence to the modeling approach and the determined entry length.     

泡沫铝的单向力学行为

本文对不同孔径的开孔泡沫铝材料的单向拉伸性能和单向压缩性能进行了研究,揭示了泡沫铝材料的变形机理,并且发现相对密度不是确定材料力学属性的唯一参数,孔径大小对材料的力学性能也有一定的影响。基于实验数据,我们讨论了材料的宏观力学性能和微观结构的联系,并利用Ramberg-Osgood模型描述了材料的单轴拉伸一维应力应变关系。     

开孔泡沫铝填充圆管的准静态压缩行为

采用开孔结构泡沫铝填充到薄壁圆形铝管中,制备出开孔泡沫铝夹芯铝管,并进行压缩实验,研究了这种结构材料的压缩力学行为和变形特征以及材料的结构特征参数对压缩力学性能和能量吸收特性的影响。在压缩过程中,泡沫铝夹芯铝管的载荷-位移曲线呈现出弹性段、波动的屈服平台段和压实段3个阶段特征;铝管的径厚比及泡沫铝本身的参数和强度对填充管的屈服强度、平均压溃力和吸能特性均有着非常显著的影响。填充泡沫铝后铝管的压缩变形方式发生改变,管壁只发生向外翻折变形,产生的环状褶皱减少。     

Particle Flow Code Method-Based Meso-scale Identification for Seepage Failure of Soil Levee

The development and validation of a grid-based pore-scale numerical modelling methodology applied to five different commercial metal foam samples is described. The 3-D digital representation of the foam geometry was obtained by the use of X-ray microcomputer tomography scans, and macroscopic properties such as porosity, specific surface and pore size distribution are directly calculated from tomographic data. Pressure drop measurements were performed on all the samples under a wide range of flow velocities, with focus on the turbulent flow regime. Airflow pore-scale simulations were carried out solving the continuity and Navier–Stokes equations using a commercial finite volume code. The feasibility of using Reynolds-averaged Navier–Stokes models to account for the turbulence within the pore space was evaluated. Macroscopic transport quantities are calculated from the pore-scale simulations by averaging. Permeability and Forchheimer coefficient values are obtained from the pressure gradient data for both experiments and simulations and used for validation. Results have shown that viscous losses are practically negligible under the conditions investigated and pressure losses are dominated by inertial effects. Simulations performed on samples with varying thickness in the flow direction showed the pressure gradient to be affected by the sample thickness. However, as the thickness increased, the pressure gradient tended towards an asymptotic value.     

Pressure drop and friction factor of steady and oscillating flows in open-cell porous media

Open-cell metal foams are often used in heat exchangers and absorption equipment because they exhibit large specific surface area and present tortuous coolant flow paths. However, published research works on the characteristics of fluid flow in metal foams are relatively scarce, especially for the flow oscillation condition. The present experimental investigation attempts to uncover the behavior of steady and oscillating flows through metal foams with a tetrakaidecahedron structure. In the experiments, steady flow was supplied by an auto-balance compressor and flow oscillation was provided by an oscillating flow generator. The pressure drop and velocity were measured by the differential pressure transducer and hot-wire sensor, respectively. The friction factor of steady flow in metal foam channel was analyzed through the permeability and inertia coefficient of the porous medium. The results show that flow resistance in the metal foams increases with increasing form coefficient and decreasing permeability. The empirical equation obtained by the present study indicates that the maximum friction factor of oscillating flow through the tested aluminum foams with specific structure is governed by the hydraulic ligament diameter-based kinetic Reynolds number and the dimensionless flow amplitude.     

Porous Medium Modeling of Air-Cooled Condensers

This article presents a porous media transport approach to model the performance of an air-cooled condenser. The finned tube bundles in the condenser are represented by a porous matrix, which is defined by its porosity, permeability, and the form drag coefficient. The porosity is equal to the tube bundle volumetric void fraction and the permeability is calculated by using the Karman–Cozney correlation. The drag coefficient is found to be a function of the porosity, with little sensitivity to the way this porosity is achieved, i.e., with different fin size or spacing. The functional form was established by analyzing a relatively wide range of tube bundle size and topologies. For each individual tube bundle configuration, the drag coefficient was selected by trial and error so as to make the pressure drop from the porous medium approach match the pressure drop calculated by the heat exchanger design software ASPEN B-JAC. The latter is a well-established commercial heat exchanger design program that calculates the pressure drop by using empirical formulae based on the tube bundle properties. A close correlation is found between the form drag coefficient and the porosity with the drag coefficient decreasing with increasing porosity. A second order polynomial is found to be adequate to represent this relationship. Heat transfer and second law (of thermodynamics) performance of the system has also been investigated. The volume-averaged thermal energy equation is able to accurately predict the hot spots. It has also been observed that the average dimensionless wall temperature is a parabolic function of the form drag coefficient. The results are found to be in good agreement with those available in the open literature.     

Hydrodynamic Characterization of Nickel Metal Foam,Part 1: Single-Phase Permeability

This article presents results of the investigation of the fluid dynamic behavior in CVD processed nickel metal foams. An experimental facility was developed to measure the single-phase permeability in nickel metal foams in Darcian flow regime. Data on permeability values of seven different nickel foam samples was obtained. The pore sizes of the foam were obtained with scanning electron microscope. By defining friction factor and Reynolds number based on the permeability length scale a correlation was obtained for the foam permeability in Darcian flow regime. The result from this study was compared with the correlations reported by other researchers, and was found to be in good agreement.     

Metal Foam Heat Exchangers for Heat Transfer Augmentation from a Cylinder in Cross-Flow

A numerical study has been conducted to examine the heat transfer from a metal foam-wrapped solid cylinder in cross-flow. Effects of the key parameters including the free stream velocity and characteristics of metal foam such as porosity, permeability, and form drag coefficient on heat and fluid flow are examined. Being a determining factor in pressure drop and heat transfer increment, the porous layer thickness is changed systematically to observe that there is an optimum layer thickness beyond which the heat transfer does not improve while the pressure drop continues to increase. This has been verified by the application of Bejan’s Intersection of Asymptotes method. Results have been compared to those of a finned-tube heat exchanger to observe much higher heat transfer rate with reasonable excess pressure drop leading to a higher area goodness factor for metal foam-wrapped cylinder.     

Effect of Compressible Foam Properties on Pressure Amplification During Shock Wave Impact

A comprehensive study is made of the influence of the physical properties of compressible open-cell foam blocks exposed to shock-wave loading, and particularly on the pressure distribution on the shock tube walls. Seven different foams are used, with three different shock Mach numbers, and three different slab lengths. Foam properties examined include permeability, density, stiffness, tortuosity and cell characteristics. The investigations concentrate on both side-wall and back-wall pressures, and the peak pressures achieved, as well as collapse velocities of the front face and the strength and nature of the reflected shock wave. The consequences of deviations from one-dimensionality are identified; primarily those due to wall friction and side-wall leakage. The results presented are the most comprehensive and wide ranging series conducted in a single facility and are thus a significant resource for comparison with theoretical and numerical studies. The different foams show significant differences in behavior, both in terms of peak pressure and duration, depending primarily on their density and permeability.This paper was based on work presented at the 2nd International Symposium on Interdisciplinary Shock Wave Research, Sendai, Japan on March 1–3, 2005.     

Flow Laws in Metal Foams: Compressibility and Pore Size Effects

The aim of our experimental work was to establish a simple relation between the flow parameters and the morphological parameters of metallic foam. We used foam samples made from different metals or alloys (Cu, Ni, Ni-Cr, etc) and of various thicknesses. Pore size ranged between 500 and 5000 μm. We measured the pressure profiles in foam samples using a specific experimental set-up of 12 pressure sensors distributed 1 cm apart along the main flow axis. The experimental loop made it possible to use indifferently water or air as working fluid. For the study of the gas (air) flow, velocities ranged roughly from 0 up to 20 m/s and for the liquid (water) flow, velocities ranged between 0 and 0.1 m/s. The measurements of the pressure gradients were performed systematically. We validated the Forchheimer flow model. The influence of the compressibility effects on permeability and inertia coefficient was emphasized. We demonstrated that the pore size Dp in itself is sufficient to describe flow laws in such high porosity material: K and β are respectively proportional to Dp² and Dp⁻¹.     

填充硅橡胶的泡沫铝复合材料的力学性能

用渗流法向开孔泡沫铝-硅合金和泡沫纯铝中充填硅橡胶获得含硅橡胶的泡沫材料, 在材料试验机和SHPB上对含硅橡胶的复合材料进行动态与准静态压缩实验。实验结果表明:含硅橡胶的泡沫复合材料只有弹性段和塑性段两个阶段,具有更高的应变率敏感性,其应力-应变曲线抖动幅度比较大。