Foam Samples Research Articles

The structural and mechanical properties of open-cell aluminum foams: Dependency on porosity, pore size, and ceramic particle addition

Aluminum foams are desired for lightweight, high-performance, and cost-effective materials, particularly in automotive, aerospace, and advanced power plants. Expansion of their applications depends on developing a detailed understanding of the structural and mechanical properties of aluminum foams. In this research, open-cell aluminum foams with 25.51–81.88 % porosity were manufactured through powder metallurgy using a space holder technique, with varying carbamide (urea) ratios (17–80 %) and particle sizes (1–1.4 mm, 1.7–2 mm, 2–2.4 mm). Three different ceramic particles, B4C, Al2O3, and SiC were used as reinforcement to improve the compression properties and energy absorption capacity of the foam materials. The study determined open and closed porosity ratios, spherical diameter, sphericity values, micropore sizes, mechanical properties, and energy absorption capacity of the foam samples both with and without ceramic additives. The results show that porosity ratio, pore size, and ceramic particle addition significantly affect aluminum foams' structural and mechanical properties, allowing for tailored properties for specific applications. It was observed that as porosity increased, compressive stress decreased, and the length of the plateau region and the shape change where densification began increased. However, there was no significant change in compressive stress and specific energy values with changing pore size. The optimal B4C addition was found to be 4 %, which significantly improved compressive strength to 3.75 MPa and specific energy to 4.24 MJ m−3.

Structure-property relationships of polydisperse open-cell foams: Application to melamine foams

The melamine foam presents a unique microstructure characterized by an interconnected network of solid struts, which form the edges and faces of high porosity open cells. This study investigates the influence of pore size distribution on acoustic properties for three commercially available melamine foams. Based on the measured transport parameters, a top-down approach is employed to determine the equivalent Kelvin-cell size corresponding to each transport parameter. The differences found in these equivalent pore sizes indicate that the mono-size model is not suitable for these materials, a difference from which a quantitative estimate of the level of polydispersity can be deduced (using macro-scale information). The polydispersity was confirmed from experimental evidence at micro-scale from the analysis of SEM images. Moreover, the measurements collected at micro-scale (average pore size and its standard deviation) can be used as input data to determine the transport and sound absorbing behavior of melamine foam samples from structure-property relationships available for open cell microstructures. This work provides evidence that the polydispersity of melamine foams should be taken into account to obtain an accurate and consistent picture of microstructure and transport properties of such open cell high porosity foams.

Measuring audible acoustic frequencies parameters of rigid porous media via an innovative impedance tube method - Solving the inverse problem

This study introduces an experimental approach to measuring audible acoustic frequency parameters of a rigid porous medium using an impedance tube. Grounded in the equivalent fluid model, a derivative of Biot's theory, our investigation delves into the propagation of waves within porous media, emphasizing the importance of effective density and dynamic compressibility of the saturated fluid. Our primary focus is on resolving the inverse problem by minimizing both experimental and theoretical absorption coefficient expressions within the audible frequency range. Concurrently, we determine four pivotal parameters: viscous and thermal permeability, the inertia factor introduced by Norris, and the thermal tortuosity introduced by Lafarge. The outcomes include a comparative analysis between experimental and simulated absorption coefficients, leveraging optimized parameters, across two distinct polyurethane foam samples.

Design of physical and functional properties of zeolitic porous monoliths by combining different foaming additives

Self-supporting zeolitic foams were synthesized by a geopolymer gel conversion process, employing silicon powder and hydrogen peroxide as foaming additives. The influence of silicon and hydrogen peroxide combination on the physical properties, mechanical characteristics, and pore distribution was studied. Correlations between these properties were drawn. This approach allows to manufacture porous monoliths tuned in terms of zeolite type and amount and characterized by bulk density ranging between 573 and 762 kg/m3 and thermal conductivity 0.33–0.53 W/mK. Pore structure, size, and distribution were dominated by the type of foaming agent: the foamed samples showed the presence of two classes of pores, the first of the order of magnitude of 1 μm, the second of the order of magnitude of 100 μm. The use of hydrogen peroxide enhanced the porosity in the meso-macropore range (0.1–5 μm). The hydrothermal treatment performed on the foamed geopolymer allowed to achieve the crystallization of zeolites within the solid geopolymer. Mainly FAU and LTA were the zeolitic phases present in the foams, whereas the use of silicon as foaming agent locally increased the Si/Al ratio on the geopolymer surface, promoting the nucleation of FAU.

Development of toxicity tests for Polyurethane foams

Polyurethanes (PUs) are a special class of polymeric materials that differ significantly from most other types of plastic in many aspects. They can be utilized in a wide range of products, including paints, coatings, elastomers, insulators, elastic fibers, and foams. PU foams are especially important as part of various convenience products. PU products often end up in landfills when they are no longer useful and can release toxic compounds when damaged by humans or microbes. Therefore, the ecotoxicological assessment of PU foams is essential. In this paper, five PU foam samples were prepared with different NCO indices (NCO-0.8, 0.9, 1.0, 1.1, and 1.2) and together with the Control sample (a previously tested non-toxic foam sample) were applied to develop toxicity tests procedure, while intentionally prepared Toxic foam has been used to verify the accuracy of the developed testing procedure. Two test organisms were successfully applied, Sinapis alba (white mustard) seeds and Escherichia coli (non-pathogenic) bacterial model organisms, and toxicity tests were adapted for the examination of PU-derived substances. Regarding Sinapis alba test, the highest NCO index (NCO-1.2) significantly reduced root length by 9.8 % compared to the Control sample. In the bacterial test, it was observed that the samples containing NCO-1.1 and NCO-1.2 had lower colony numbers (5.0 × 108 and 4.9 × 108 CFU/mL respectively) in comparison to the Control plate (9.6 × 108 CFU/mL). All in all, two toxicity tests were successfully adapted for PU foams, and both are applicable in their ecotoxicological assessment.

Foam density measurement using a 3D scanner

In this work, we used a 3D scanner for the volume measurement of foamed samples, a long-standing problem in the density evaluation of foams. The 3D scanning density measurement method can be selected as an alternative to or in combination with well-established, classical methods that involve the use of instruments like a caliper, a pycnometer, or other devices based on displacement or flotation principles. In particular, the classical methods show some limitations when the foamed sample geometry is irregular, when the polymer is highly hygroscopic, and when it has open porosities. We have tested numerous foamed samples of different sizes, shapes, densities, materials, and morphologies. We utilized different 3D scanner configurations for their volume measurement and compared the results with geometrical and displacement methods, when possible. Results showed that the proposed method is highly accurate, reproducible, and simple, although some specific precautions should be put in place to avoid misinterpretation by the shape-reconstructing software.

Simple Nickel Foam Modification Procedures for Enhanced Ni Foam Supercapacitor Applications

The three-dimensional and porous structure of nickel foam makes it an attractive material for employment in cost-effective electrochemical supercapacitors. This communication presents ac. impedance spectroscopy and cyclic voltammetry electrochemical examinations of potential supercapacitor electrode materials, fabricated by means of simple electrochemical procedures, employed to as-received Ni foam material. This involves the electro-oxidation and Co-catalytic modifications of baseline nickel foam samples. Hence, the supercapacitor-type performance (as evidenced over the examined potential range in 0.1 M NaOH solution) of base nickel foam material could extensively be tailored by means of simple surface and catalytic refinements. The latter was evidenced through the employment of combined electrochemical (cyclic voltammetry, ac. impedance) and SEM/EDX (Scanning Electron Microscopy/Energy Dispersive X-Ray) surface spectroscopy evaluations.

Deep Indentation Tests of Soft Materials Using Mobile and Stationary Devices.

Measurements of the properties of soft materials are important from the point of view of medical diagnostics of soft tissues as well as testing the quality of food products and many technical materials. One of the frequently used techniques for testing such materials, attractive due to its non-invasive nature, is the indentation technique, which does not puncture the material. The difficulty of testing soft materials, which affects the objectivity of the results, is related to the problems of stable positioning of the studied material in relation to the indentation apparatus, especially with a device held by the operator. This work concerns the comparison of test results using an indentation apparatus mounted on mobile and stationary handles. The tested materials are cylindrical samples of polyurethane foams with three different stiffnesses and the same samples with a 0.5 or 1 mm thick silicone layer. The study presented uses an apparatus with a flat cylindrical indenter, with a surface area of 1 cm2, pressed to a depth of 10 mm (so-called deep tests). Based on the recorded force changes over time, five descriptors of the indentation test were determined and compared for both types of handles. The tests performed showed that the elastic properties of foam materials alone and with a silicone layer can be effectively characterized by the maximum forces during recessing and retraction and the slopes of the recessing and retraction curves. In the case of two-layer materials, these descriptors reflect both the characteristics of the foams and the silicone layer. The results show that the above property of the deep indentation method distinguishes it from the shallow indentation method. The repeatability of the tests performed in the mobile and stationary holders were determined to be comparable.

Modeling the thermal behavior of multifunctional syntactic foams containing phase change materials for heat management applications

AbstractSyntactic foams are lightweight porous composites obtained by the addition of hollow glass microspheres (HGMs) to a polymer matrix. This work experimentally and numerically investigates the thermal behavior of epoxy‐based syntactic foams with enhanced multifunctionality produced by incorporating microencapsulated phase change materials (PCMs) as functional fillers, providing thermal energy storage and temperature stabilization due to its large latent heat of melting. Foams are fabricated using varying ratios of HGMs (0–40 vol%) and PCM (0–40 vol%) to achieve tuned densities and thermal properties with a total filler content of up to 40 vol%. A one‐dimensional numerical heat transfer model based on the enthalpy method is presented to simulate the thermal behavior of these materials. The model accurately incorporates the specific heat and thermal conductivity of the foam components, as well as the latent heat absorption during PCM melting (up to 68 J/g). The model is experimentally validated by demonstrating good agreement with the measurements of transient temperature profiles during heating tests on the foam samples. The validated tool is then leveraged to model the thermal response of the foams under a sinusoidally varying heat source, similar to the possible real applicative scenarios. These results can help optimize foam compositions balancing energy storage density, heat transfer properties, and structural support for lightweight energy storage systems. Potential applications include high‐efficiency thermal management in battery packs, electronic cooling, solar energy storage, and sustainable temperature‐controlled buildings.Highlights Foams with 0–40 vol% PCM and 0–40 vol% HGM show up to 68 J/g latent heat. 1D numerical model accurately captures thermal conductivity and PCM phase change. Validated model simulates thermal response under sinusoidal heat, optimizing foam composition. Foams act as thermal reservoirs, maintaining up to 5°C lower surface temperatures than epoxy.

Optimization of Foams-Polypropylene Fiber-Reinforced Concrete Mixtures Dedicated for 3D Printing.

The continued global urbanization of the world is driving the development of the construction industry. In order to protect the environment, intensive research has been carried out in recent years on the development of sustainable materials and ecological construction methods. Scientific research often focuses on developing building materials that are renewable, energy-efficient, and have minimal impact on the environment throughout their life cycle. Therefore, this article presents research results aimed at developing a concrete mixture using cement with reduced CO2 emissions. In the context of increasing ecological awareness and in line with European Union policy, the development of a mixture based on environmentally friendly cement is of key importance for the future development of the construction industry. The article compares the physical properties of two mixtures, their foaming possibilities, and the influence of the added polypropylene (PP) fibers on the strength properties of the produced composites. It was found that bending strength and compressive strength were highest in the material with silica fume and aluminum powder at 5.36 MPa and 28.76 MPa, respectively. Microscopic analysis revealed significant pore structure differences, with aluminum foamed samples having regular pores and hydrogen peroxide foamed samples having irregular pores. Optimizing aluminum powder and water content improved the materials' strength, crucial for maintaining usability and achieving effective 3D printing. The obtained results are important in the development of research focused on the optimization of 3D printing technology using concrete.

Evaluating the mechanism and the capacitive properties of nickel boride electrodes for supercapacitor applications

This study investigates the electrochemical properties of nickel boride electrodes produced via a novel molten salt boron diffusion method; known as cathodic reduction and thermal diffusion-based boriding (CRTD-Bor). Pure nickel substrates with two different geometries (i.e. flat and foam) were borided in the borax-based electrolyte. The presence of nickel borides, composed of NiB, Ni4B3 and Ni2B with the order locations from the surface towards the matrix, was confirmed by X-ray diffractometry (XRD) and scanning electron microscopy (SEM) attached with electron probe microanalyzer (EPMA). The electrochemical behaviors of the produced electrodes were inspected through cyclic voltammetry (CV), galvanostatic charge-discharge (GCD), as well as impedance spectroscopy (EIS). The areal capacitances of the electrodes were calculated as 478 and 1385 mF/cm2 for flat and foam samples, respectively after the 2000th cycle of CV at 10 mV/s scan rate. The reaction kinetic followed the mixed-controlled model according to the Trasatti approach. The capacitive contribution (Co) measured in flat samples was 71 %; whereas, it was found as 40.6 % in the foam-shaped electrodes. Additionally, the mechanism behind the faradaic reactions was explored through X-ray photoelectron spectroscopy (XPS) and Fourier Transform Infrared Spectroscopy (FTIR) which were conducted both before and after the CV experiments. The obtained results showed that the possible mechanism was related to the formation of NiO bonds due to the oxygen saturation in the defective regions of the surfaces during electrochemical testing. Moreover, the importance of the electrode geometry on the performance was determined by the fact that the porous structure leads to more energy storage and favors a fast charge-discharge trend.

Fabrication of flat and sizeable nanocellular polymethyl methacrylate (PMMA) foam with tunable thermal conductivity

AbstractPolymeric nanocell foam is a promising material that faces manufacturing challenges. Producing sizable and thick foams for properties testing has been challenging. This study aims to scale up and understand the foaming mechanism of nanocellular foams by controlling the saturation temperature, pressure, and molecular weight distribution of the matrix to fine‐tune the glass transition temperature of the polymer/gas mixture. The hot‐press foamed samples possess a 100 × 70 × 6 ~ 8 mm3 dimension and a cell size of less than 200 nm. Bimodal structures can also be created by controlling the critical processing parameters. Introducing 37% microcells into unimodal nanocellular foam reduced the relative density from 0.29 to 0.19. The thermal conductivity of the foams was tuned by controlling the cell size distribution. Unimodal nanofoams have the lowest thermal conductivity for foams of the same density due to the Knudsen effect and tortuosity. The measured thermal conductivity is in agreement with theoretical models.Highlights PMMA nanofoam with a dimension of 100 × 70 × 6–8 mm3 and cell size below 200 nm. The morphology of nanofoams was tuned to be unimodal and bimodal. The foam density of the bimodal nanofoams was lowered below 0.238 g/cm3. The thermal conductivity of foams was tuned by controlling the cell structure.

Atomistic-to-continuum modeling of carbon foam: A new approach to finite element simulation

Carbon foam materials exhibit useful characteristics for unique and diverse applications. However, accurately modeling three-dimensional carbon foam remains a significant challenge. This paper introduces a novel technique for transitioning atomistic-scale models of porous carbon, obtained via molecular dynamics simulation, to continuum-scale carbon foam models suited for finite element simulations. We present our method using the fractal properties of porous media, specifically carbon foams. The resulting models demonstrate testable properties consistent with those derived from computed tomography (CT) scans and experimental data. Stress–strain curves obtained from finite element analysis (FEA) calculations of our models correlate well with experimental measurements from dogbone testing samples of carbon foam sourced from CONSOL Innovations LLC, WV, USA, as well as CT scan models derived from the carbon foams. Our approach presents a computationally efficient alternative and encourages innovation in modeling porous media, particularly in extracting physical properties from an ensemble of models.

Effects of Gamma-Synthesized Chitosan on Morphological, Thermal, Mechanical, and Heavy-Metal Removal Properties in Natural Rubber Foam as Sustainable and Eco-Friendly Heavy Metal Sorbents

The properties of natural rubber foam (NRF) containing gamma-synthesized chitosan (CS) powder were investigated to address the growing demand for efficient methods to treat industrial wastewater contaminated with heavy metals. The CS powder was prepared by irradiating chitin (CT) powder with varying doses of gamma rays (0–100 kGy), followed by deacetylation using 40% sodium hydroxide (NaOH) at 100 °C for 1 h. The resulting CS powders were then mixed with natural rubber latex (NRL) at different contents (0, 3, 6, and 9 parts per hundred parts of rubber by weight; phr) and processed using Dunlop techniques to prepare the foam samples. The experimental findings indicated that the degree of deacetylation (%DD) of the CS powder increased initially with gamma doses up to 60 kGy but then decreased at 80 and 100 kGy. In addition, when the CS powder was incorporated into the NRF samples, there were increases in total surface area, density, compression set, and hardness (shore OO), with increasing gamma doses and CS contents. Furthermore, the determination of heavy metal adsorption properties for Cu, Pb, Zn, and Cd showed that the developed NRF sample exhibited high adsorption capacities. For instance, their removal efficiencies reached 94.9%, 82.5%, 91.4%, and 97.0%, respectively, in NRF containing 9 phr of 60 kGy CS. Notably, all adsorption measurements were determined using 3 cm × 3 cm × 2.5 cm specimens submerged in respective metal solutions, with an initial concentration of 25 mg/L. However, the removal capacity per unit mass of the sample (mg/g) showed less dependencies on CS contents, probably due to the higher density of CS/NRF composites in comparison to pristine NRF, resulting in a smaller volume of the former being submerged in the solution, subsequently suppressing the effects from CS in the adsorption. Lastly, tests on the reusability of the developed NRF indicated that the samples could be reused for up to three cycles, with the Cu removal capacity remaining relatively high (83%) in the sample containing 9 phr of 60 kGy CS. The overall outcomes implied that the developed NRF with the addition of gamma-synthesized CS not only offered effective and eco-friendly heavy metal adsorption capacity to improve public health safety and the environment from industrial wastewater but also promoted greener and safer procedures for the synthesis/modification of similar substances through radiation technologies.

Fabrication of lightweight polyethersulfone foams with enhanced surface quality and high specific flexural properties using micro‐opening microcellular injection molding

AbstractPolyethersulfone (PES) is distinguished by its exceptional comprehensive properties, making it a highly valued engineering plastic employed in various cutting‐edge fields. However, the high cost of PES limits its wider application in industrial fields. Considering the cost‐reduction advantages of polymer foaming, PES foams were successfully prepared in this work using microcellular injection molding (MIM) and micro‐opening microcellular injection molding (MOMIM) foaming methods. Compared with the MIM foaming method, the PES foam samples prepared by the MOMIM foaming method have better microcellular structure and surface quality. As the micro‐opening distance increased, the cell density of the PES foam samples showed a gradual rise before plateauing, with the cell size remaining relatively constant. As a result, the density of the PES foam sample dropped to 1.07 g/cm3, which is 80.5% of the solid PES sample. Meanwhile, the mechanical properties of the PES foam samples remained robust, with both the specific flexural modulus and the specific flexural strength showing increases as the micro‐opening distance increased. The knowledge obtained from this study provides a method for preparing high‐performance PES foam materials, which will facilitate the application of PES in more civilian fields.

Foam density mapping via THz imaging

Plastic foams, near-ubiquitous in everyday life and industry, show properties that depend primarily on density. Density measurement, although straightforward in principle, is not always easy. As such, while several methods are available, plastic foam industry is not yet supported with a standard technique that effectively enables to control density maps. To overcome this issue, this paper proposes Terahertz (THz) time-of-flight imaging using normal reflection measurements as a fast, relatively cheap, contactless, non-destructive and non-dangerous way to map plastic foam density, based on the expected relationship between density and refractive index. The approach is demonstrated in the case of polypropylene foams. First, the relationship between the estimated effective refractive index and the polypropylene foam density is derived by characterizing a set of carefully crafted samples having uniform density in the range 70–900 kg/m3. The obtained calibration curve subtends a linear relationship between the density and the refractive index in the range of interest. This relationship is validated against a set of test samples, whose estimated average densities are consistent with the nominal ones, with an absolute error lower than 10 kg/m3 and a percentage error on the estimate of 5%. Exploiting the calibration curve, it is possible to build quantitative images depicting the spatial distribution of the sample density. THz images are able to reveal the non-uniform density distribution of some samples, which cannot be appreciated from visual inspection. Finally, the complex spatial density pattern of a graded foam sample is characterized and quantitatively compared with the density map obtained via X-ray microscopy. The comparison confirms that the proposed THz approach successfully determines the density pattern with an accuracy and a spatial scale variability compliant with those commonly required for plastic foam density estimate.

Waste heat recovery from exhaust gases using porous metal fins: a three-dimensional numerical study

Abstract The objective of this study is to investigate the impact of different porous metal samples on the hydro-thermal characteristics of a single cylinder with porous fins using computational fluid dynamics. Commercially used porous samples with pore densities of 10, 20, and 40 PPI were used in this study for heat recovery from exhaust flue gas. The three-dimensional computational domain with porous aluminium fins attached to a tube over which high-temperature exhaust gas flows in a crossflow arrangement mimics a waste heat recovery system. Computations were performed at Reynolds number of 6000-9000, using the realisable κ-ϵ turbulence model. Three fin diameter to tube diameter ratios (Df/D = 2, 2.5, and 3) were considered. The local thermal non-equilibrium model is implemented for energy transfer, as it is more accurate for a high-temperature gradient scenario in a waste heat recovery system. The foam sample with the highest pore density was observed to have the highest pressure drop due to low permeability. A maximum heat transfer and Nusselt number were achieved for a 40 PPI foam sample due to a reduced flow rate inside the porous zone. The overall performance of metal foam samples at varying fin diameters was evaluated based on the area goodness factor (j/f) and a heat transfer coefficient ratio to pumping power per unit heat transfer surface (Z/E). Analysis of these two parameters suggests using 20 PPI foam at Df/D = 2.

Effect of Gentamicin Sulfate and Polymeric Polyethylene Glycol Coating on the Degradation and Cytotoxicity of Iron-Based Biomaterials.

The work is focused on the degradation, cytotoxicity, and antibacterial properties, of iron-based biomaterials with a bioactive coating layer. The foam and the compact iron samples were coated with a polyethylene glycol (PEG) polymer layer without and with gentamicin sulfate (PEG + Ge). The corrosion properties of coated and uncoated samples were studied using the degradation testing in Hanks' solution at 37 °C. The electrochemical and static immersion corrosion tests revealed that the PEG-coated samples corroded faster than samples with the bioactive PEG + Ge coating and uncoated samples. The foam samples corroded faster compared with the compact samples. To determine the cytotoxicity, cell viability was monitored in the presence of porous foam and compact iron samples. The antibacterial activity of the samples with PEG and PEG + Ge against Escherichia coli CCM 3954 and Staphylococcus aureus CCM 4223 strains was also tested. Tested PEG + Ge samples showed significant antibacterial activity against both bacterial strains. Therefore, the biodegradable iron-based materials with a bioactive coating could be a suitable successor to the metal materials studied thus far as well as the materials used in the field of medicine.

Effect of free particles in porous media on pool boiling heat transfer performance

We conducted a comprehensive investigation into the mechanisms the enhancement of pool boiling heat transfer. Created a porous medium composite free particle reinforced structure (FPPM). FPPM is synthesized with copper foam (Cu foam) with a porous structure as the base material; it is characterized by free particles inside the cavity. We used deionized water (DI water) as the working fluid to study the heat transfer performance of pool boiling on different surfaces under atmospheric pressure. The boiling mechanism was verified by bubble dynamics. The findings showed that the addition of free particles to the copper foam sample significantly reduced the superheating of its onset of nucleate boiling (ONB). Compared to the polished surface, a maximum of 2.57 times the heat transfer coefficient was achieved; in addition, a maximum of 1.59 times the heat transfer coefficient was achieved compared to the copper foam surface without free particles. The visualization results showed the formation of nucleation sites on the surface with free particles, which decreased the energy barrier to easy nucleation. During the boiling process of the pool, the high thermal conductivity of free particles and the disturbance to the gas–liquid layer significantly reduced the bubble detachment frequency, resulting in good heat transfer performance over the whole range of heat fluxes.

Functional LSMO foams for magneto-caloric applications

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