Compressive response of open-cell foams. Part I: Morphology and elastic properties

This study is concerned with the understanding and modeling of the compressive response of open cell foams. The response starts with a nearly linear elastic regime which terminates into a limit load followed by an extensive load plateau. The plateau, which is responsible for the excellent energy absorption capacity of foams, is followed by a second stiff branch. Results from polyester urethane open cell foams with relative densities of about 0.025 are used to illustrate this behavior using experiments coupled with several levels of modeling. The experiments include characterization of the microstructure and the properties of the base material and measurement of the compressive response of the foams of various cell sizes.A sequence of models for predicting the complete response of such foam is developed. The foam is idealized to be periodic using the space-filling Kelvin cell assigned the major geometric characteristics found in the foams tested. The cells are elongated in the rise direction, the ligaments are assumed to be straight, to have Plateau border cross-sections and nonuniform cross-sectional area distribution. The ligaments are modeled as shear-deformable extensional beams and the base material is assumed to be linearly elastic. Prediction of the initial elastic moduli are addressed in Part I. Closed form expressions for the material constants are presented as well as results using a FE model of the characteristic cell. Comparison between measurements and predictions is very favorable. The paper finishes with results from a limited parametric study of the elastic moduli. The results demonstrate that inclusion of the geometric complexities mentioned above is essential for successful prediction of the moduli of such foams. The nonlinear parts of the response including the foam crushing behavior are addressed in Part II.     

Three-dimensional modeling of the mechanical property of linearly elastic open cell foams

Three-dimensional Voronoi models are developed to investigate the mechanical behavior of linearly elastic open cell foams. Dependence of the Young’s modulus, Poisson’s ratio and bulk modulus of the foams on the relative density is evaluated through finite element analysis. Obtained results show that in the low density regime the Young’s modulus and bulk modulus of random Voronoi foams can be well represented by those of Kelvin foams, and are sensitive to the geometric imperfections inherent in the microstructure of foams. In contrast, the compressive plateau stress of the foams is less sensitive to the imperfections. Failure surface of the foams subject to multi-axial compression is determined and is found to comply with the maximum compressive principal stress criterion, consistent with available experimental observations on polymer foams. Numerical results also show that elastic buckling of cell edges at microscopic level is the dominant mechanism responsible for the compressive failure of elastic open cell foams.     

On the microstructure of open-cell foams and its effect on elastic properties

Synthetic open-cell foams have a complex microstructure consisting of an interconnected network of cells resulting from the foaming process. The cells are irregular polyhedra with anywhere from 9 to 17 faces in nearly monodisperse foams. The material is concentrated in the nearly straight ligaments and in the nodes where they intersect. The mechanical properties of such foams are governed by their microstructure and by the properties of the base material. In this study micro-computed X-ray tomography is used to develop 3D images of the morphology of polyester urethane and Duocel aluminum foams with different average cell sizes. The images are used to establish statistically the cell size and ligament length distributions, material distributions along the ligaments, the geometry of the nodes and cell anisotropy. The measurements are then used to build finite element foam models of increasing complexity that are used to estimate the elastic moduli. In the most idealized model the microstructure is represented as a regular Kelvin cell. The most realistic models are based on Surface Evolver simulations of random soap froth with N³ cells in spatially periodic domains. In all models the cells are elongated in one direction, the ligaments are straight but have a nonuniform cross sectional area distribution and are modeled as shear deformable beams. With this input both the Kelvin cell models and the larger random foam models are shown to predict the elastic moduli with good accuracy but the random foams are 5–10% stiffer.     

Impact of material processing and deformation on cell morphology and mechanical behavior of polyurethane and nickel foams

The cell morphology and mechanical behavior of open-cell polyurethane and nickel foams are investigated by means of combined 3D X-ray micro-tomography and large scale finite element simulations. Our quantitative 3D image analysis and finite element simulations demonstrate that the strongly anisotropic tensile behavior of nickel foams is due to the cell anisotropy induced by the deformation of PU precursor during the electroplating and heat treatment stages of nickel foam processing. In situ tensile tests on PU foams reveal that the initial main elongation axis of the cells evolves from the foam sheet normal direction to the rolling direction of the coils. Finite element simulations of the hyperelastic behavior of PU foams based on real cell morphology confirm the observation that cell struts do not experience significant elongation after 0.15 tensile straining, thus pointing out alternative deformation mechanisms like complex strut junctions deformation. The plastic behavior and the anisotropy of nickel foams are then satisfactorily retrieved from finite element simulations on a volume element containing eight cells with a detailed mesh of all the hollow struts and junctions. The experimental and computational strategy is considered as a first step toward optimization of process parameters to tailor anisotropy of cell shape and mechanical behavior for applications in batteries or Diesel particulate filtering.     

On the compressive strength of open-cell metal foams with Kelvin and random cell structures

Two families of finite element models of anisotropic, aluminum alloy, open-cell foams are developed and their predictions of elastic properties and compressive strength are evaluated by direct comparison to experimental results. In the first family of models, the foams are idealized as anisotropic Kelvin cells loaded in the <100> direction and in the second family more realistic models, based on Surface Evolver simulations of random soap froth with N³ cells are constructed. In both cases the ligaments are straight but have nonuniform cross sectional area distributions that resemble those of the foams tested. The ligaments are modeled as shear deformable beams with elasto-plastic material behavior. The calculated compressive response starts with a linearly elastic regime. At higher stress levels, inelastic action causes a gradual reduction of the stiffness that eventually leads to a stress maximum, which represents the strength of the material. The periodicity of the Kelvin cell enables calculation of the compressive response up to the limit stress with just a single fully periodic characteristic cell. Beyond the limit stress, deformation localizes along the principal diagonals of the microstructure. Consequently beyond the limit stress the response is evaluated using finite size 3-D domains that allow the localization to develop. The random models consist of 3-D domains of 216, 512 or 1000 cells with periodicity conditions on the compressed ends but free on the sides. The compressive response is also characterized by a limit load instability but now the localization is disorganized resembling that observed in experiments. The foam elastic moduli and strengths obtained from both families of models are generally in very good agreement with the corresponding measurements. The random foam models yield 5–10% stiffer elastic moduli and slightly higher strengths than the Kelvin cell models. Necessary requirements for this high performance of the models are accurate representation of the material distribution in the ligaments and correct modeling of the nonlinear stress–strain response of the aluminum base material.     

Dynamic crushing behavior of honeycomb structures with irregular cell shapes and non-uniform cell wall thickness

Dynamic crushing responses of honeycomb structures having irregular cell shapes and non-uniform cell wall thickness are studied using the Voronoi tessellation technique and the finite element (FE) method. FE models are constructed for such honeycomb structures based on Voronoi diagrams with different degrees of cell shape irregularity and cell wall thickness non-uniformity. The plateau stress, the densification strain energy and the initiation strain are determined using the FE models. Simulation results reveal that the “X” and “V” shaped deformation modes evident in a perfectly ordered honeycomb at low or moderate impact velocities are disrupted as cell shapes become irregular and/or cell wall thickness gets non-uniform. The “I” shaped deformation mode is clearly seen in all honeycomb structures at high impact velocities. Both the plateau stress and the densification strain energy are found to decrease as the degree of cell shape irregularity or the degree of cell wall thickness non-uniformity increases, with the weakening effect induced by the presence of non-uniform cell wall thickness being more significant. When the two types of imperfections co-exist in a honeycomb structure, the interaction between them is seen to exhibit a complicated pattern and to have a nonlinear effect on both the plateau stress and the densification strain energy. It is also found that stress waves propagate faster in a honeycomb structure having irregular cell shapes and slower in a honeycomb structure having non-uniform cell wall thickness than in a perfectly ordered honeycomb. Finally, the strain hardening of the cell wall material is seen to have a strengthening effect on the plateau stress, which is more significant for perfectly ordered honeycombs than for imperfect honeycomb structures.     

Compressive response and failure of braided textile composites: Part 2—computations

In this, the second part of a two part paper, results obtained by using the finite element (FE) method in conjunction with micromechanics to predict the effective elastic stiffness and strength of a carbon 2D triaxially braided composite (2DTBC), are presented. The 3D FE based micromechanics study was carried out on one representative unit cell (RUC) of the carbon 2DTBC (the “micromodel”). The FE models were first used to determine the macroscopic elastic orthotropic stiffnesses of the 2DTBC. The micromodel was deemed acceptable (in terms of the number of elements used in the mesh of the micromodel) if the elastic stiffnesses it displayed were within 5% of the elastic properties found experimentally. Subsequently, buckling eigenmodes were determined for the FE RUC under uniaxial and biaxial loading states, corresponding to the experimental investigation reported in part I of this two part paper. The lowest symmetric modes were identified and these mode shapes were used as imperfections to the FE model for a subsequent nonlinear response analysis using an arc-length method in conjunction with the ABAQUS commercial FE code. The magnitude of the imperfections was left as a parameter and its effect on the predicted response was quantified. The present micromechanics computational model provides a means to assess the compressive and compressive/tensile biaxial strength of the braided composites and its dependence on various microstructural parameters. It also serves as a tool to assess the most significant parameter that affects compressive strength.     

Effective elastic behavior of some models for perfect cellular solids

The effective elastic behavior of some models for low density cellular solids, or solid foams, are calculated using analytical and numerical techniques. The models are perfect in the sense that imperfections or irregularities as often encountered in real foams have been removed. We believe that the present models can serve as references to which more advanced models which include imperfections and irregularities can be compared. The work in this paper does not address buckling or yielding in cell walls, which play an increasingly important role as foam stresses increase.     

Modelling open cell-foams based on the Weaire–Phelan unit cell with a minimal surface energy approach

The complex architecture of open cell foams has most often been described by Kelvin cell models. It has been shown that the accuracy to predict the elastic properties of open cell foams increases with an increasing level of detail and resemblance to real foam microstructures. However, the Kelvin cell does not possess pentagonal faces which are the most abundant within real open cell foams. Therefore this study focuses on the use of the Weaire–Phelan unit cell to model the elastic properties of an open cell polyurethane foam. Optical and scanning electron microscopy were used to characterise the architecture of the open cell foam. Surface Evolver software was used to minimize the surface energy and introduce the typical architectural characteristics of the open cell foam to the FE-model. The E-modulus and Poisson coefficient of the Kelvin and Weaire–Phelan cell show a similar behaviour as a function of density. The Weaire–Phelan cell predicts however a higher dependency of the shear modulus on the density. When the influence of the elongation of the cells in the rise direction of the foam and the uncertainty of the solid material properties of the polyurethane is taken into account, a good accuracy of the Kelvin cell and Weaire–Phelan structure based FE-models versus experimental compression tests is found.     

Kelvin结构开孔泡沫材料的弹性性能研究

采用一修正的十四面体结构模型(Kelvin结构模型)对开孔泡沫金属的弹性性能进行研究,对低密度开孔泡沫材料表现出不可压的特性进行了分析。该模型考虑作用在泡沫筋条上的弯矩、剪力和轴向力,以及轴向力的平衡。修正模型的数值计算结果与实验结果及其他模型的结果进行了对比,结果表明修正模型计算的杨氏模量比原有模型的略有提高,筋条截面为星形的修正模型计算的结果与实验比较符合。在密度等同的条件下,筋条截面惯性矩越大的开孔泡沫材料,其弹性模量也越大,而泊松比则越小。Kelvin结构的开孔泡沫材料的泊松比随相对密度的减小而趋于0.5。     

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.     

Attenuation of shock waves propagating in polyurethane foams

Shock wave attenuation in polyurethane foams is investigated experimentally and numerically. This study is a part of research project regarding shock propagation in polyurethane foams with high-porosities = 0.951 ~ 0.977 and low densities of ρc = 27.6 ~55.8 kg/m³. Sixty Millimeter long cylindrical foams with various cell numbers and foam insertion condition were installed in a horizontal shock tube of 50 mm i.d. and 5.4 mm in length. Results of pressure measurements in air/foam combination are compared with CFD simulation solving the one-dimensional Euler equations. In the case of a foam B fixed on shock tube wall, pressures at the shock tube end wall increases relatively slowly comparing to non-fixed foam, free to move and a foam A fixed on shock tube wall. This implies that elastic inertia hardly contributes to pressure build up. Pressures behind a foam C fixed on shock tube wall decrease indicating that shock wave is degenerated into compression wave. Dimensionless impulse and attenuation factor decrease as the initial cell number increases. The momentum loss varies depending on cell structure and cell number.     

Modeling and prediction of bulk properties of open-cell carbon foam

The emerging ultralightweight material, carbon foam, was modeled with three-dimensional microstructures to develop a basic understanding in correlating microstructural configuration with bulk performance of open-cell foam materials. Because of the randomness and complexity of the microstructure of the carbon foam, representative cell ligaments were first characterized in detail at the microstructural level. The salient microstructural characteristics (or properties) were then correlated with the bulk properties through the present model. In order to implement the varying anisotropic nature of material properties in the foam ligaments, we made an attempt to use a finite element method to implement such variation along the ligaments as well as at a nodal point where the ligaments meet. The model was expected to provide a basis for establishing a process-property relationship and optimizing foam properties.The present model yielded a fairly reasonable prediction of the effective bulk properties of the foams. We observed that the effective elastic properties of the foams were dominated by the bending mode associated with shear deformation. The effective Young's modulus of the foam was strongly influenced by the ligament moduli, but was not influenced by the ligament Poisson's ratio. The effective Poisson's ratio of the foam was practically independent of the ligament Young's modulus, but dependent on the ligament Poisson's ratio. The effective Young's modulus of the carbon foam was dependent more on the transverse Young's modulus and the shear moduli of the foam ligaments, but less significantly on the ligament longitudinal Young's modulus. A parametric study indicated that the effective Young's modulus was significantly improved by increasing the solid modulus in the middle of the foam ligaments, but nearly invariant with that at the nodal point where the ligaments meet. Therefore, appropriate processing schemes toward improving the transverse and shear properties of the foam ligaments in the middle section of the ligaments rather than at the nodal points are highly desirable for enhancing the bulk moduli of the carbon foam.     

基于三维细观力学模型的开孔泡沫弹性性能预测

泡沫材料的宏观力学性能主要取决于基体材料的力学特性及其微细观结构特征,基于细观力学模型的分析方法是泡沫材料力学性能研究的重要途径。文中基于Matlab语言和Abaqus软件构建了描述中等孔隙率开孔弹性泡沫材料微结构特征的三维随机分布球形泡孔模型,并采用有限元方法对弹性泡沫压缩变形进行了模拟,并计算给出了不同孔隙率弹性泡沫材料弹性模量、剪切模量、体积模量以及泊松比的分布,建立了相应的唯象表达式。与理论模型及测试结果的比较表明,本文基于三维随机泡孔模型模拟结果构建的唯象表达式能够对弹性泡沫材料的弹性力学性能给出很好的预测。     

Modeling the dynamic response of visco-elastic open-cell foams

This article introduces a mesoscopic formulation for modeling the dynamic response of visco-elastic, open-cell solid foams. The effective material response is obtained by enforcing on a representative 3D unit cell the principle of minimum action for dissipative systems. The resulting model accounts explicitly for the foam topology, the elastic and viscous properties of the cell wall, and the inertial effects arising from non-affine motion within the cells. The microinertial effects become significant in retarding the foam collapse during exceedingly high strain-rate loading. As an application example, a heterogenous case of compressive deformation at high strain rate is simulated utilizing the present model as a constitutive update in a non-linear finite element analysis code. This FEM simulation shows the ability of the model to capture the progressive foam collapse during the dynamic compression as observed in experimental studies. Using the microscopic model, the inertial and viscous strain-rate effects are investigated through the foam density, viscosity, and relative density. Based on the physics incorporated into the local cell model, we provide insight into the physical mechanisms responsible for the experimentally observed strain-rate effects on the behavior of dynamically loaded foam materials.     

Mindlin second-gradient elastic properties from dilute two-phase Cauchy-elastic composites Part II: Higher-order constitutive properties and application cases

Starting from a Cauchy elastic composite with a dilute suspension of randomly distributed inclusions and characterized at first-order by a certain discrepancy tensor (see part I of the present article), it is shown that the equivalent second-gradient Mindlin elastic solid: (i) is positive definite only when the discrepancy tensor is negative defined; (ii) the non-local material symmetries are the same of the discrepancy tensor, and (iii) the non-local effective behaviour is affected by the shape of the RVE, which does not influence the first-order homogenized response. Furthermore, explicit derivations of non-local parameters from heterogeneous Cauchy elastic composites are obtained in the particular cases of: (a) circular cylindrical and spherical isotropic inclusions embedded in an isotropic matrix, (b) n-polygonal cylindrical voids in an isotropic matrix, and (c) circular cylindrical voids in an orthotropic matrix.     

Buckling behavior of Kelvin open-cell foams under [0 0 1], [0 1 1] and [1 1 1] compressive loads

This paper describes buckling modes and stresses of elastic Kelvin open-cell foams subjected to [0 0 1], [0 1 1] and [1 1 1] uniaxial compressions. Cubic unit cells and cell aggregates in model foams are analyzed using a homogenization theory of the updated Lagrangian type. The analysis is performed on the assumption that the struts in foams have a non-uniform distribution of cross-sectional areas as observed experimentally. The relative density is changed to range from 0.005 to 0.05. It is thus found that long wavelength buckling and macroscopic instability primarily occur under [0 0 1] and [0 1 1] compressions, with only short wavelength buckling under [1 1 1] compression. The primary buckling stresses under the three compressions are fairly close to one another and almost satisfy the Gibson–Ashby relation established to fit experiments. By also performing the analysis based on the uniformity of strut cross-sectional areas, it is shown that the non-uniformity of cross-sectional areas is an important factor for the buckling behavior of open-cell foams.     

The high strain mechanical response of the wet Kelvin model for open-cell foams

Surface Evolver software was used to create the three-dimensional geometry of a Kelvin open-cell foam, to simulate that of polyurethane flexible foams. Finite Element Analysis (FEA) with 3D elements was used to model large compressive deformation in the [0 0 1] and [1 1 1] directions, using cyclic boundary conditions when necessary, treating the polyurethane as an elastic or elastic–plastic material. The predicted foam Young’s moduli in the [0 0 1] direction are double those of foams with uniform Plateau border cross-section edges, for the same foam density and material properties. For compression in the [1 1 1] direction, the normalized Young’s modulus increases from 0.9 to 1.1 with foam relative density, and the predicted stress–strain relationship can have a plateau, even for a linearly-elastic polymer. As the foam density increases, the predicted effects of material plasticity become larger. For foam of relative density 0.028, edge-to-edge contact is predicted to occur at a 66% strain for [1 1 1] direction compression. The foam is predicted to contract laterally when the [1 1 1] direction compressive strain exceeds 25%.     

Elastic properties of model random three-dimensional open-cell solids

Most cellular solids are random materials, while practically all theoretical structure-property relations are for periodic models. To generate theoretical results for random models the finite element method (FEM) was used to study the elastic properties of open-cell solids. We have computed the density (ρ) and microstructure dependence of the Young's modulus (E) and Poisson's ratio (ν) for four different isotropic random models. The models were based on Voronoi tessellations, level-cut Gaussian random fields, and nearest neighbour node-bond rules. These models were chosen to broadly represent the structure of foamed solids and other (non-foamed) cellular materials. At low densities, the Young's modulus can be described by the relation E∝ρⁿ. The exponent n and constant of proportionality depend on microstructure. We find 1.3<n<3, indicating a more complex dependence than indicated by periodic cell theories, which predict n=1 or 2. The observed variance in the exponent was found to be consistent with experimental data. At low densities we found that ν≈0.25 for three of the four models studied. In contrast, the Voronoi tessellation, which is a common model of foams, became approximately incompressible (ν≈0.5). This behaviour is not commonly observed experimentally. Our studies showed the result was robust to polydispersity and that a relatively large number (15%) of the bonds must be broken to significantly reduce the low-density Poission's ratio to ν≈0.33.