Foamed Research Articles

Effect of foaming behavior of polypropylene foams on flame retardant properties under different weight reduction methods

AbstractIn previous studies, the effect of cell structures of polypropylene (PP) foam materials on flammability behavior had been largely overlooked. In this work, ammonium polyphosphate and pentaerythritol were used as intumescent flame retardants (IFR) for PP, and then the PP‐IFR flame retardant foams were prepared by using injection foaming technology with two different weight reduction methods (same mold volume before foaming and after foaming). The results showed that the average cell size of all the PP‐IFR flame retardant foams in the 10% to 30% weight reduction was less than 100 μm. The PP‐IFR flame retardant foams with an average cell diameter of 26.22 μm and cell density of 7.88 × 106 cells/cm3 had the best limiting oxygen index (LOI) of 27.9%. In addition, the PP‐IFR flame retardant foams with better foaming quality had a higher LOI and a denser foam carbon layer whatever the weight reduction methods, resulting in better flame retardant properties. The escape of gases from the foamed and un‐foamed areas not only reduced the concentration of flammable gases but also led to the collapse and rupture of the foam carbon layer during the combustion process. Hence, it provides guidance for preparing PP foam materials with excellent flame retardancy.

Effect of Reinforcement on Micro Structural and Compressive Deformation Behavior on Closed Cell AA7075 Aluminium Foam

Effect of Reinforcement on Micro Structural and Compressive Deformation Behavior on Closed Cell AA7075 Aluminium Foam

Effect of phase evolution and pyroplastic formation behavior on glass-ceramic foam derived from silicomanganese slag and feldspar tailings

Utilizing solid waste to produce foam material has become a significant direction in resource recycling. This study focuses solely on using silicomanganese slag and feldspar tailings as raw materials, utilizing a powder sintering process to produce autocatalytic foaming glass–ceramic foam. We formulated four mix ratios based on the compositional characteristics of the silicomanganese slag and feldspar tailings. The study then explored the evolution of phase formation and macroscopic pore morphology under varying preparation temperatures. Moreover, through multi-phase co-melting experiments, this work unveiled the high-temperature molten mass generation mechanism between silicomanganese slag and feldspar tailings. Our findings reveal that the glass melt generated from silicomanganese slag particles and the 'solid–liquid erosion behavior' of feldspar particles play pivotal roles in the formation of high-temperature co-melt substances. As the sintering temperature increases, the mixed powder exhibits three different states of high-temperature molten mass, which are the reasons for the evolution of the macroscopic pore structure. It is suggested that the addition of silicomanganese slag should be less than 50 %, and the heat treatment temperature should be below 1145 °C in preparing glass–ceramic foam with silicomanganese slag and feldspar tailings. The sample with 40 % silicomanganese slag and 60 % feldspar tailings, treated at 1140 °C, yielded glass–ceramic foam with a compressive strength of 1.68 MPa, apparent density of 0.279 g/cm3, porosity of 81.7 %, and thermal conductivity of 0.074 W·m−1·K−1. In summary, this study provides a novel approach for the high-value utilization of silicomanganese slag and offers an economical route for developing lightweight, eco-friendly structural materials.

Tailoring the Mass Density of 3D Printing Materials for Accurate X-ray Imaging Simulation by Controlled Underfilling for Radiographic Phantoms.

Additive manufacturing and 3D printing allow for the design and rapid production of radiographic phantoms for X-ray imaging, including CT. These are used for numerous purposes, such as patient simulation, optimization of imaging procedures and dose levels, system evaluation and quality assurance. However, standard 3D printing polymers do not mimic X-ray attenuation properties of tissues like soft, adipose, lung or bone tissue, and standard materials like liquid water. The mass density of printing polymers-especially important in CT-is often inappropriate, i.e., mostly too high. Different methods can be applied to reduce mass density. This work examines reducing density by controlled underfilling either realized by using 3D printing materials expanded through foaming during heating in the printing process, or reducing polymer flow to introduce microscopic air-filled voids. The achievable density reduction depends on the base polymer used. When using foaming materials, density is controlled by the extrusion temperature, and ranges from 33 to 47% of the base polymer used, corresponding to a range of -650 to -394 HU in CT with 120 kV. Standard filaments (Nylon, modified PLA and modified ABS) allowed density reductions by 20 to 25%, covering HU values in CT from -260 to 77 (Nylon), -230 to -20 (ABS) and -81 to 143 (PLA). A standard chalk-filled PLA filament allowed reproduction of bone tissue in a wide range of bone mineral content resulting in CT numbers from 57 to 460 HU. Controlled underfilling allowed the production of radiographic phantom materials with continuously adjustable attenuation in a limited but appropriate range, allowing for the reproduction of X-ray attenuation properties of water, adipose, soft, lung, and bone tissue in an accurate, predictable and reproducible manner.

Cellulose fiber-based and engineered capillary foam toward a sustainable, recyclable, and high-performance cushioning structural material

Foam materials have been widely used in cushioning packaging to ensure the integrity of products inside by absorbing energy and preventing collision. However, the extensive use of petroleum-based plastic foams may exacerbate environmental pollution and consume large amounts of energy. Therefore, there has been an increasing focus on producing high-performance and environmentally friendly foams in recent years. In this study, we developed a simple approach for manufacturing cellulose fiber-based capillary foams featuring superior stability and three-dimensional (3D) backbone network cross-linking structure composed of polyvinyl alcohol (PVA) and cationic starch (CS). The resultant capillary foam showed low density (0.154 g/cm3), superior mechanical properties (elastic modulus ranging from 77 to 501 kPa), high energy absorbing efficiency (32.8 %), and low cushioning coefficient (3.0). Besides, the end-of-life cellulose fiber-based capillary foam can be easily recycled for use, showing an attractive closed-loop cycle process. This study presents a unique option for creating affordable, eco-friendly, and malleable foams, demonstrating the potential to substitute the currently used petroleum-based foams in the packaging, food, and transport industries.

Non-enzymatic Glucose Sensor Based on Ni(OH)2/NF Materials Using Different Pulse Voltammetry Technique

Non-enzymatic glucose sensors have gained significant attention owing to their potential for accurate and cost-effective glucose detection. Nanomaterials play a pivotal role in enhancing performance of non-enzymatic glucose sensor. In this study, a novel non-enzymatic glucose sensor based on Ni(OH)2/NF (nickel hydroxide/nickel foam) materials was developed using different pulse voltammetry technique. Chemical precipitation methods have been used to grow Ni(OH)2 nanostructures directly on a nickel foam electrode. The characterization of the synthesized materials was performed through field emission scanning electron microscopy (FESEM), energy dispersive spectroscopy (EDX), and X-ray diffraction (XRD). The performance of the Ni(OH)2/NF-based glucose sensor was evaluated through electrochemical measurements. Nanoscale hive-like structures of Ni(OH)2 with a diameter ranging from 450 to 530 μm and a thickness of 20 nm were formed on the NF surface. The sensor exhibited good performance, displaying a high sensitivity of 8.42mA.mM-1.cm-2 with a low detection limit of 0.84 μM. These results position the synthesized electrode as a promising contender for non-enzymatic electrochemical glucose sensors.

The Preparation and Performance of Epoxy/Acetylene Carbon Black Wave-Absorbing Foam.

The epoxy foam material filled with an absorbing agent effectively absorbs electromagnetic waves. In this study, epoxy resin was used as the matrix, and acetylene carbon black was used as the magnetic absorbing agent to prepare an absorbing foam material (epoxy/CB). The microstructure of acetylene carbon black (CB) and its distribution in epoxy resin, as well as the effects of pre-polymerization time and CB content on the foam structure, were systematically characterized. Additionally, two dispersion methods, the hot-melt in situ stirring dispersion method and the three-roll milling dispersion method, were studied for their effects on the foaming process and absorbing properties of epoxy/CB. The results showed that with the prolongation of pre-polymerization time, the pore size decreased from 1.02 mm to 0.4 mm, leading to a more uniform pore distribution. Compared to the hot-melt in situ stirring dispersion method, the three-roll milling dispersion method effectively improved the dispersion of CB in epoxy resin, reducing the aggregate size from 300-400 nm to 70-80 nm. The pore diameter also decreased from 0.453 mm to 0.311 mm, improving the uniformity of particle size distribution. However, the absorbing material prepared with the three-roll milling dispersion method exhibited unsatisfactory absorption performance, with values close to 0 dB at mid-low frequencies and around -1 dB at high frequencies. In contrast, the absorbing material prepared with the hot-melt in situ stirring dispersion method showed better absorption performance at high frequencies, reaching around -9 dB.

Parametric investigation of battery thermal management system with phase change material, metal foam, and fins; utilizing CFD and ANN models

The focus on developing an effective battery thermal management system (BTMS) to maintain optimal temperatures for lithium-ion batteries (LIBs), especially in electric vehicle (EV) applications, has grown significantly. The effective BTMS not only enhances the cooling performance of LIBs but also contributes to increased passenger safety and mileage of EVs. This study investigates BTMS configurations with fins, metal foam, and phase change material (PCM) to minimize temperature of battery during 3C discharging in varying conditions. Additionally, the study explores the impact of different BTMS material combinations and various fins lengths on system performance as a parametric investigation. Moreover, to streamline the analysis process and introduce novelty, artificial intelligence is explored as an alternative to computational fluid dynamics for predicting liquid fraction of PCM and temperature of battery, enhancing the innovative aspect of this study. Numerical simulations, using a non-equilibrium thermal model for metal foam modeling, reveal that the fourth case, integrating all three passive approaches, maintains the lowest temperature and enhances LIB cooling. The optimum BTMS shows a reduction of 3 K compared to BTMS utilizing pure PCM. During discharge process, the temperature difference in the battery decreases by approximately 75 % and 66 % in the fourth case compared to the first case (with pure PCM) under normal and harsh environmental conditions, respectively. Applying copper metal foam and copper fins yields the best results in reducing battery temperature. Increasing the length of fins and adding more fins effectively lower the battery temperature. Finally, an artificial neural network model is developed using the backpropagation learning technique coupled with the gradient descent optimization algorithm. The model exhibits excellent predictive capabilities, achieving high R-squared values of 0.98 for PCM liquid fraction and 0.99 for battery temperature.

Preparation of Shrink-Resistant Environmentally Friendly Foam

The shrinkage issue has posed a significant challenge for the practical application of biodegradable foam materials. The varying temperature-pressure mode (VT-PM) was adopted to fabricate poly (butylene adipate-butylene terephthalate) (PBAT)/Polybutylene succinate (PBS) foams. Foam shrinkage was significantly improved by the synergistic effect of temperature and pressure, and the shrinkage resistance mechanism was investigated by analyzing the cell structure. The crystallization behavior of PBS was investigated using differential scanning calorimetry (DSC) and polarized optical microscope (POM). Small size PBS crystals were obtained during the temperature change process, and the heterogeneous nucleation of PBS crystals increased the foaming expansion ratio. It was also found that the thick cell wall was able to act as a skeleton to support the structure of large cell size (＞100 μm) foams, ensuring larger compression stress and modulus.

Numerical simulation of heat transfer performance in an enclosure filled with a metal foam and nano-enhanced phase change material

Nowadays phase change materials are widely used in different engineering systems to perform effective cooling techniques for heat-generating elements or to accumulate the thermal energy effectively. The disadvantage of the phase change material is a low thermal conductivity, but it can be improved using porous media or metal nanoadditives of high thermal conductivity. The present research is devoted to the mathematical simulation of conjugate thermal convection in a closed chamber partially filled with metal foam saturated with nano-enhanced phase change material. The governing equations have been formulated using the Oberbeck-Boussinesq equations with the Stefan problem approach for the liquid phase and the heat conduction equation for the solid phase. The finite difference technique in combination with non-primitive variables has been used for numerical analysis. The developed in-house numerical program has been verified using the grid independence test as well as the experimental and theoretical outcomes of other authors. The effects of the metal foam properties and nanoadditives characteristics on melt behavior and thermal energy transport parameters have been studied. The main attention is paid to the influence of a filling height ratio of the metal foam on the heat transport process. It has been revealed that the impact of the metal foam on thermal dissipation is essentially higher compared to the nanoadditives influence. Therefore, in the case of full height foam, the effect of nanoparticles is weak, but in the cavity with a partial height of the porous medium, NePCM can be melted faster than pure PCM and has a negative effect on the heater temperature. It has been also found that changing the filling height ratio from 0.167 to 0.5 does not lead to a significant change in the temperature of the heater.

Numerical investigations on the impact of metallic foam configurations on heat transfer in double tube heat exchanger: A parametric approach

In this research, a parametric analysis of partially filled high-porosity metallic foams within a double-tube heat exchanger integrated into a solar flat plate collector is conducted. The primary objective is to comprehensively analyze the thermal and fluid flow behavior in this complex system through numerical simulations employing ANSYS Fluent v2021, with water as the working fluid. The study encompasses three distinct metal foam materials—Nickel, Copper, and Aluminum—each investigated across six cases with varying porosities (ranging from 0.80 to 0.90) and pore densities (ranging from 10 to 30). The investigation also explores changes in the internal diameter of the foams adjacent to the conduit wall and the external diameter of the foam within the tube core, resulting in multiple test cases. Rigorous validation of simulation results against experimental data enhances the credibility of the findings. To simulate fluid flow and heat transfer phenomena within the metal foam heat exchanger’s intricate geometry, the research leverages the Reynolds-Averaged Navier-Stokes (RANS) equations coupled with the k-epsilon model, treating the metal foam as a porous medium. The outcomes reveal intriguing insights, such as the close thermal performance match between 10 PPI aluminum foam and the more costly 10 PPI copper foam. The highest performance factor is observed for 30 PPI aluminum foam, highlighting its efficiency. However, the performance factor exhibits variations, with values of 2.03, 3.15, and 3.73 for 100 PPI, 20 PPI, and 30 PPI foams, respectively, and their corresponding porosities of 0.90, 0.85, and 0.80 in case 1, case 2, and case 3, all at a lower Reynolds number of 3,000. This performance factor decreases progressively with increasing fluid flow rates. Additionally, the research evaluates key parameters, including average wall temperature, average Nusselt number, and Colburn j factor, to identify the optimal performance characteristics within the investigated configurations. This study provides valuable insights into the potential for enhancing the efficiency of heat exchangers in solar flat plate collectors through the strategic utilization of high-porosity metallic foams.

Performance evaluation of a partially-filled porous foam cylindrical tubular receiver realizing Ni foam material reduction

The optimization of metal foam structure parameters is crucial for enhancing the heat transfer and pressure drop performance of cylindrical tube heat exchangers. In this study, thermal output performance of 16 different nickel foam-filled solar receivers with varying thicknesses and positions is numerically simulate. An optical-thermal conversion model is established using the Monte Carlo ray tracing (MCRT) method and user-defined functions. The influences of foam filling thickness and position on heat absorber, wall hot spot distribution, heat loss type, thermal efficiency, pressure drop, thermohydraulic performance, exergy loss, and outlet temperature were analyzed. Furthermore, a multi-objective optimization algorithm called non-dominated sorting genetic algorithm II (NSGA II) is used to generate the best trade-off solutions between improvement of thermal efficiency and pressure drop. The results show that enhancing the thickness of the filled foam within the CTR tube enhances thermal efficiency and elevates pressure drop. However, optimizing the length and filling position of the foam can effectively mitigate excessive pressure drop caused by longer foam, without compromising thermal efficiency. This approach results in a reduced pressure drop while maintaining optimal performance. The optimal solution of multi-objective optimization is that the 123 mm thickness foam is filled at 0 mm from the inlet of the tube, and the pressure drop and thermal efficiency of the solar receiver are 830.2Pa and 83.1 %, respectively, when the mass flow rate is 0.01 kg/s.

Influence of key design variables on dynamic material properties of iron tailing porous concrete under impact loading

Iron tailing porous concrete (ITPC) is a new foamed concrete material that using iron ore tailing powder to partially replace the cement. Previous investigations on ITPC primarily focused on its mechanical properties under static loads or low strain rate conditions, leaving a significant gap in its impact resistance performance at high strain rates. This study employed the split Hopkinson pressure bar (SHPB) to test ITPC specimens under impact loading with strain rate around 120 s−1. Density, water-binder (W/B) ratio, iron tailing powder content, polypropylene fiber length and content were taken as key design variables to prepare the ITPC specimens with different mix ratios and study their effects on the dynamic material properties of ITPC. Specifically, the failure modes, stress-strain relations, elastic moduli, compressive strengths and energy dissipation densities of the ITPC specimens with various design variables were recorded and compared. The test results indicate that the material density, fiber length and content have strong influences on the impact failure modes of ITPC. The elastic modulus, compressive strength and energy dissipation density of ITPC exhibit exponential growth with the material density. These parameters, however, show an initial growth followed by a decrease with the rising W/B ratio, fiber length and fiber content, and they reach the peak values at around 0.70, 9 mm and 2.0%, respectively. Moreover, the iron tailing powder content of 25% is recommended for ITPC for maintaining good impact resistance.

Modeling Xanthan Gum Foam's Material Properties Using Machine Learning Methods.

Xanthan gum is commonly used in the pharmaceutical, cosmetic, and food industries. However, there have been no studies on utilizing this natural biopolymer as a foam material in the insulation and packaging sectors, which are large markets, or modeling it using an artificial neural network. In this study, foam material production was carried out in an oven using different ratios of cellulose fiber and xanthan gum in a 5% citric acid medium. As a result of the physical and mechanical experiments conducted, it was determined that xanthan gum had a greater impact on the properties of the foam material than cellulose. The densities of the produced foam materials ranged from 49.42 kg/m3 to 172.2 kg/m3. In addition, the compressive and flexural moduli were found to vary between 235.25 KPa and 1257.52 KPa and between 1939.76 KPa and 12,736.39 KPa, respectively. Five machine-learning-based methods (multiple linear regression, support vector machines, artificial neural networks, least squares methods, and generalized regression neural networks) were utilized to analyze the effects of the components used in the foam formulation. These models yielded accurate results without time, material, or cost losses, making the process more efficient. The models predicted the best results for density, compression modulus, and flexural modulus achieved in the experimental tests. The generalized regression neural network model yielded impressive results, with R2 values above 0.97, enabling the acquisition of more quantitative data with fewer experimental results.

Preparation of foam material via co-sintering of NaCl and PTFE for oil/water separation

Preparation of foam material via co-sintering of NaCl and PTFE for oil/water separation

Water-dispersible X-ray scintillators enabling coating and blending with polymer materials for multiple applications

Developing X-ray scintillators that are water-dispersible, compatible with polymeric matrices, and processable to flexible substrates is an important challenge. Herein, Tb3+-doped Na5Lu9F32 is introduced as an X-ray scintillating material with steady-state X-ray light yields of 15,800 photons MeV−1, which is generated as nanocrystals on halloysite nanotubes. The obtained product exhibits good water-dispersibility and highly sensitive luminescence to X-rays. It is deposited onto a polyurethane foam to afford a composite foam material with dose-dependent radioluminescence. Moreover, the product is dispersed into polymer matrixes in aqueous solution to prepare rigid or flexible scintillator screen for X-ray imaging. As a third example, it is incorporated multilayer hydrogels for information camouflage and multilevel encryption. Encrypted information can be recognized only by X-ray irradiation, while the false information is read out under UV light. Altogether, we demonstrate that the water-dispersible scintillators are highly promising for aqueous processing of radioluminescent, X-ray imaging, and information encrypting materials.

Lightweight polypropylene/BaTiO3 composite foams with tunable dielectric constant

Lightweight dielectric foam materials with tunable dielectric constant of 2–1 have broad application prospects in the field of Luneburg lens. Expandable polystyrene (EPS) foam is commonly used for fabricating discrete dielectric layers of Luneburg lens, while its temperature resistance and mechanical properties are poor. EPS foam with dielectric constant of >1.5 is also difficult to prepare because of its low expansion ratio. In this work, choosing polypropylene (PP) with better temperature resistance and mechanical properties as polymer matrix, PP/BaTiO3 composite foams are fabricated by subcritical CO2 batch foaming and steam-chest molding. Through the dual regulation of expansion ratio and mold-opening distance, the dielectric constant of PP/BaTiO3 foams can be tunable from ∼1.19 to ∼1.91, with the density increasing from ∼0.14 to ∼0.59 g/cm3. Compared with EPS foams, PP/BaTiO3 foams have lower density under the similar dielectric constant, indicating the weight reduction of polymer dielectric foam materials by introducing high dielectric fillers.

Preparation, Structure and Properties of Epoxy/Carbonyl Iron Powder Wave-Absorbing Foam for Electromagnetic Shielding.

The application of absorbing materials for electromagnetic shielding is becoming extensive, and the use of absorbents is one of the most important points of preparing absorbing foam materials. In this work, epoxy resin was used as the matrix and carbonyl iron powder (CIP) was used as the absorbent, and the structural absorbing foam materials were prepared by the ball mill dispersion method. Scanning electron microscopy showed that the CIP was evenly dispersed in the resin matrix. The foam structures formed at pre-polymerization times of 10 min, 30 min and 50 min were analyzed, and it was found that the cell diameter decreased from 0.47 mm to 0.31 mm with the increase in the pre-polymerization time. The reflectivity of the frontal and reverse sides of the foam gradually tends to be unified at frequencies of 2-18 GHz. When the CIP content increased from 30 wt% to 70 wt%, the cell diameter increased from 0.32 mm to 0.4 mm, and the uniformity of CIP distribution deteriorated. However, with the increase in the CIP content, the absorption properties of the composite materials were enhanced, and the absorption frequency band broadened. When the CIP content reached 70 wt%, the compression strength and modulus of the foam increased to 1.32 MPa and 139.0 MPa, respectively, indicating a strong ability to resist deformation.

Research on the performance of pavement crack repair materials based on foaming polyurethane

In this paper, Pucs, a new two-component foaming polyurethane material, is selected to carry out a feasibility study on its application in pavement crack repair. Based on the two common crack repair materials in current projects, tests of pavement performance of repair materials are carried out, such as bonding performance, water damage resistance performance, high-temperature performance, and aging resistance performance. The comparative analysis of the results reveals that Pucs have better pavement performance than conventional crack repair materials. This indicates that Pucs is a new kind of material with excellent performance in pavement crack repair and can be widely used in the field of crack repair.

Compression testing of EPP bead foams in a vacuum chamber: Experimental investigation on the influence of the cell gas

In this study, we systematically investigate the compression behavior of Expanded Polypropylene (EPP) bead foams using precise experiments in a custom-designed vacuum chamber. The material’s response is examined under controlled pressure conditions, including compression tests at both ambient pressure and 4 mbar, at various strain rates. Considering that most foams consist of more than 90% air, our focus is on elucidating the influence of cell gas on mechanical properties, such as compression modulus, plateau stress, plateau slope, and energy absorption. The impact of cell gas on recovery behavior was analyzed by loading–unloading-steps in the vacuum chamber. Notably, the presence of cell gas shows a pronounced effect on the foam’s deformation behavior, particularly in the plateau region, significantly affecting its resistance to deformation and energy absorption. The findings offer valuable insights for the development of foam materials and structures/components made of foams, especially in applications where resilience and durability are paramount.