Investigation of cell shape effect on the mechanical behaviour of open-cell metal foams

The mechanical behaviours of metal foams greatly depend on their cell topology, including cell shape, cell size etc. as well as relative density and material properties of the cell wall. However, the cell shape effect on the mechanical behaviours of such materials appears to be ignored in previous research. In this paper, both analytic and finite element models are developed and employed to investigate the effect of cell shape on the mechanical behaviour of open-cell magnesium alloy (AZ91) foams under compression, including deformation modes and failure modes. For numerical modelling, both two-dimensional (2-D) and three-dimensional (3-D) finite element models are developed to predict the compressive behaviours of typical open-cell metal foams and capture the deformation modes and failure mechanisms. Two typical cell shapes i.e. cubic and diamond are taken into consideration. To validate these models, the analytic and numerical results are compared to the experimental data. Both the numerical and experimental data indicate that the cell shape significantly affects the compression behaviour of open-cell metal foams. In general, numerical results from the three-dimensional solid-element model show better agreement with the experimental results than those from other finite element models.

Digital material representation and testing of metal foams

In recent years, metal foams are becoming more and more popular due to their high energy absorption ability and low density, which are being widely used in automotive engineering and aerospace engineering. As a design guide, foams can be characterised by several main geometric parameters, such as pore size, pore shape, spatial distribution and arrangement and so on. Considering most foam materials have random distributions of cell size and cell shape, the digital material representation and modelling of such materials become more complex. Cell size and shape effects on mechanical behaviours of metal foams have been found and investigated numerically and experimentally in authors' previous studies in which the authors have developed a digital framework for the representation, modelling and evaluation of multi-phase materials including metal foams. In this study, 2-/3-D finite element models are both developed to represent metal foams with random cell distributions and then a series of digital testing are simulated to investigate the mechanical behaviours of such foams. For validation and verification purpose, the results obtained from 2-/3-D models have been compared and good agreement has been found which demonstrated the effectiveness of the digital framework developed for metal forms. © (2014) Trans Tech Publications, Switzerland.

Automotive engineering metal foam structures: fabrication, characterisation, testing and simulation

The contrubution of this thesis is to generate fundamental research and design information on the impact and bending behaviours of metal foams and foam-filled tubes

Mechanical properties of micro-porous metals produced by space-holding sintering

Micro-porous nickel foams with an open cell structure were fabricated by the space-holding sintering. The average pore size of the micro-porous nickel specimens ranged from 30 μm to 150 μm, and the porosity ranged from 60 % to 80 %. The porous characteristics of the nickel specimens were observed using scanning electron microscopy (SEM). The mechanical properties were studied using compressive tests. For comparison, macro-porous nickel foams prepared by the chemical vapour deposition method with pore sizes of 800 μm and 1300 μm and porosity of 95 % were also presented. Results indicated that the ratio value of 6 and higher for the specimen length to cell size (L/d) is satisfying for obtaining stable compressive properties. The micro-porous nickel specimens exhibited different deformation behaviour and dramatically increased mechanical properties, compared to those of the macro-porous nickel specimens.

Fabrication of novel metal alloy foams for biomedical applications

Degeneration of the weight bearing bones of the ageing population often requires the inception of metallic biomaterials. Research in this area is receiving increased attention globally. However, most of today's artificial bone materials are dense and suffer from problems of adverse reaction, biomechanical mismatch and lack of appropriate space for the regeneration of new bone tissues. In the present study, novel ZrTi alloy foams with a porous structure and mechanical properties that are very close to those of bone were fabricated. These ZrTi alloy foams are biocompatible, and display a porous structure permitting the ingrowth of new bone tissues.

Biomechanical properties of porous metal scaffolds as implant materials

The results obtained from this work reveal that high porous titanium foams have fracture mechanical properties that meet and exceed the required properties of both cortical and cancellous bones. With their good biocompatibility, light weight, strong structural integrity and possibility of bone in-growth these foams are suitable for biomedical applications.

Sulfur-doped porous reduced graphene oxide hollow nanosphere frameworks as metal-free electrocatalysts for oxygen reduction reaction and as supercapacitor electrode materials.

Chemical doping with foreign atoms is an effective approach to significantly enhance the electrochemical performance of the carbon materials. Herein, sulfur-doped three-dimensional (3D) porous reduced graphene oxide (RGO) hollow nanosphere frameworks (S-PGHS) are fabricated by directly annealing graphene oxide (GO)-encapsulated amino-modified SiO2 nanoparticles with dibenzyl disulfide (DBDS), followed by hydrofluoric acid etching. The XPS and Raman spectra confirmed that sulfur atoms were successfully introduced into the PGHS framework via covalent bonds. The as-prepared S-PGHS has been demonstrated to be an efficient metal-free electrocatalyst for oxygen reduction reaction (ORR) with the activity comparable to that of commercial Pt/C (40%) and much better methanol tolerance and durability, and to be a supercapacitor electrode material with a high specific capacitance of 343 F g(-1), good rate capability and excellent cycling stability in aqueous electrolytes. The impressive performance for ORR and supercapacitors is believed to be due to the synergistic effect caused by sulfur-doping enhancing the electrochemical activity and 3D porous hollow nanosphere framework structures facilitating ion diffusion and electronic transfer.

'Laser chemistry' synthesis, physicochemical properties, and chemical processing of nanostructured carbon foams

Laser ablation of selected coordination complexes can lead to the production of metal-carbon hybrid materials, whose composition and structure can be tailored by suitably choosing the chemical composition of the irradiated targets. This 'laser chemistry' approach, initially applied by our group to the synthesis of P-containing nanostructured carbon foams (NCFs) from triphenylphosphine-based Au and Cu compounds, is broadened in this study to the production of other metal-NCFs and P-free NCFs. Thus, our results show that P-free coordination compounds and commercial organic precursors can act as efficient carbon source for the growth of NCFs. Physicochemical characterization reveals that NCFs are low-density mesoporous materials with relatively low specific surface areas and thermally stable in air up to around 600°C. Moreover, NCFs disperse well in a variety of solvents and can be successfully chemically processed to enable their handling and provide NCF-containing biocomposite fibers by a wet-chemical spinning process. These promising results may open new and interesting avenues toward the use of NCFs for technological applications.

Stabilizing and destabilizing protein surfactant-based foams in the presence of a chemical surfactant: Effect of adsorption kinetics.

Stimuli-responsive protein surfactants promise alternative foaming materials that can be made from renewable sources. However, the cost of protein surfactants is still higher than their chemical counterparts. In order to reduce the required amount of protein surfactant for foaming, we investigated the foaming and adsorption properties of the protein surfactant, DAMP4, with addition of low concentrations of the chemical surfactant sodium dodecylsulfate (SDS). The results show that the small addition of SDS can enhance foaming functions of DAMP4 at a lowered protein concentration. Dynamic surface tension measurements suggest that there is a synergy between DAMP4 and SDS which enhances adsorption kinetics of DAMP4 at the initial stage of adsorption (first 60s), which in turn stabilizes protein foams. Further interfacial properties were revealed by X-ray reflectometry measurements, showing that there is a re-arrangement of adsorbed protein-surfactant layer over a long period of 1h. Importantly, the foaming switchability of DAMP4 by metal ions is not affected by the presence of SDS, and foams can be switched off by the addition of zinc ions at permissive pH. This work provides fundamental knowledge to guide formulation using a mixture of protein and chemical surfactants towards a high performance of foaming at a low cost.