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Dynamic crushing behavior of closed-cell aluminum foams based on different space-filling unit cells

Talebi S., Hedayati R., Sadighi M.

Archives of Civil and Mechanical Engineering

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2021

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Vol. 21, no. 3

231--245

EN

Closed-cell metal foams are cellular solids that show unique properties such as high strength to weight ratio, high energy absorption capacity, and low thermal conductivity. Due to being computation and cost effective, modeling the behavior of closed-cell foams using regular unit cells has attracted a lot of attention in this regard. Recent developments in additive manufacturing techniques which have made the production of rationally designed porous structures feasible has also contributed to recent increasing interest in studying the mechanical behavior of regular lattice structures. In this study, five different topologies namely Kelvin, Weaire–Phelan, rhombicuboctahedron, octahedral, and truncated cube are considered for constructing lattice structures. The effects of foam density and impact velocity on the stress–strain curves, first peak stress, and energy absorption capacity are investigated. The results showed that unit cell topology has a very significant effect on the stiffness, first peak stress, failure mode, and energy absorption capacity. Among all the unit cell types, the Kelvin unit cell demonstrated the most similar behavior to experimental test results. The Weaire–Phelan unit cell, while showing promising results in low and medium densities, demonstrated unstable behavior at high impact velocity. The lattice structures with high fractions of vertical walls (truncated cube and rhombicuboctahedron) showed higher stiffness and first peak stress values as compared to lattice structures with high ratio of oblique walls (Weaire–Phelan and Kelvin). However, as for the energy absorption capacity, other factors were important. The lattice structures with high cell wall surface area had higher energy absorption capacities as compared to lattice structures with low surface area. The results of this study are not only beneficial in determining the proper unit cell type in numerical modeling of dynamic behavior of closed-cell foams, but they are also advantageous in studying the dynamic behavior of additively manufactured lattice structures with different topologies.

2

Low-velocity impact behaviour of open-cell foams

Hedayati R., Sadighi M.

Journal of Theoretical and Applied Mechanics

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2018

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Vol. 56 nr 4

939--949

EN

Metal foams are cellular solids that show some unique properties which cannot be found in other natural or human-made materials. While the impact characteristics of closed-cell foams under static and impact loadings appear to be well-studied in the literature, the impact behaviour of open-cell foams is not yet well-understood. In this study, open-cell foams with two different densities are impacted by drop weights with different kinetic energies. The effects of foam density, impactor initial height, and impactor weight on the recorded stresstime, stress-strain, and energy-strain curves are investigated. While the stress-strain curve of closed-cell foams under impact loading usually consists of a single bell, the results of the current study showed that both the stress-time and stress-strain curves of most the samples consist of two consecutive bells. By increasing weight of the impacting weight, the number of bells increases which helps in increasing the impact period and keeping the maximum generated stress low. Compared to closed-cell foams, the open-cell foams can therefore better absorb the energy, as long as the impact energy is relatively small. The relatively low stiffness as well as the presence of large hollow space inside the open-cell foams also makes them favorable for being used as biomedical scaffolds.

3

Numerical and experimental study of the mechanical response of aluminum foams under compressive loading using CT data

Mohammadi Nasrabadi A. A., Hedayati R., Sadighi M.

Journal of Theoretical and Applied Mechanics

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2016

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Vol. 54 nr 4

1357--1368

EN

Metal foams are relatively novel materials that due to excellent mechanical, thermal, and insulation properties have found wide usage in different engineering applications such as energy absorbers, bone substitute implants, sandwich structure cores, etc. In common numerical studies, the mechanical properties of foams are usually introduced to FE models by considering homogenized uniform properties in different parts of a foamy structure. However, in highly irregular foams, due to complex micro-geometry, considering a uniform mechanical property for all portions of the foam leads to inaccurate results. Modeling the micro-architecture of foams enables better following of the mechanisms acting in micro-scale which would lead to more accurate numerical predictions. In this study, static mechanical behavior of several closed-cell foam samples has been simulated and validated against experimental results. The samples were first imaged using a multi-slice CT-Scan device. Subsequently, experimental compression tests were carried out on the samples using a uniaxial compression testing machine. The CT data were then used for creating micro-scale 3D models of the samples. According to the darkness or brightness of the CT images, different densities were assigned to different parts of the micro-scale FE models of the foam samples. Depending on density of the material at a point, the elastic modulus was considered for it. Three different formulas were considered in different simulations for relating the local elastic modulus of the foam material to density of the foam material at that point. ANSYS implicit solver was used for the simulations. Finally, the results of the FE models based on the three formulas were compared to each other and to the experimental results to show the best formula for modeling the closed-cell foams.

4

A micromechanical approach to numerical modeling of yielding of open-cell porous structures under compressive loads

Hedayati R., Sadighi M.

Journal of Theoretical and Applied Mechanics

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2016

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Vol. 54 nr 3

769--781

EN

Today, interconnected open-cell porous structures made of titanium and its alloys are replacing the prevalent solid metals used in bone substitute implants. The advent of additive manufacturing techniques has enabled manufacturing of open-cell structures with arbitrary micro-structural geometry. In this paper, rhombic dodecahedron structures manufactured using SLM technique and tested by Amin Yavari et al. (2014) are investigated numerically using ANSYS and LS-DYNA finite element codes for the modeling of the elastic and postyielding behavior of the lattice structure, respectively. Implementing a micro-mechanical approach to the numerical modeling of the yielding behavior of open-cell porous materials is the main contribution of this work.One of the advantages of micro-mechanical modeling of an open-cell structure is that, in contrast to the macro-mechanical finite element modeling, it is not necessary to obtain several material constants for different foam material models through heavy experimental tests. The results of the study showed that considering the irregularity in defining the cross-sections of the struts decreases both the yielding stress and densification strain of the numerical structure to the values obtained from the experimental tests. Moreover, the stress-strain curve of the irregular structure was much smoother in two points of yielding and densification, which is also observable in experimental plots. Considering the irregularity in the structure also decreased the elastic modulus of the lattice structure by about 20-30%. The post-densification modulus was more influenced by irregularity as it was decreased by more than 50%. In summary, it was demonstrated that using beam elements with variable cross-sections for constructing open-cell biomaterials could result in numerical results sufficiently close to the experimental data.