Open-cell Cellular Structures Research Articles

About the surface area to volume relations of open cell foams

Many useful applications of solid open-cell foams make use of their enormous surface, compared to their volume. The large surface is accompanied by a large interface between foam and filling of a fluid, gas or another solid forming a composite material. Due to the large interface, heat exchange between the involved materials takes place in a particularly efficient manner making open cell metallic foams to base materials for heat exchange and heat systems of increasing importance. But what is the mathematical connection between the solid bulk volume fraction and the surface of these porous materials? This question is investigated through the evaluation of 5000 synthetic, randomly generated open-cell cellular structures of different material ratios.

Fatigue and biological properties of Ti-6Al-4V ELI cellular structures with variously arranged cubic cells made by selective laser melting.

Traditional implants made of bulk titanium are much stiffer than human bone and this mismatch can induce stress shielding. Although more complex to produce and with less predictable properties compared to bulk implants, implants with a highly porous structure can be produced to match the bone stiffness and at the same time favor bone ingrowth and regeneration. This paper presents the results of the mechanical and dimensional characterization of different regular cubic open-cell cellular structures produced by Selective Laser Melting (SLM) of Ti6Al4V alloy, all with the same nominal elastic modulus of 3GPa that matches that of human trabecular bone. The main objective of this research was to determine which structure has the best fatigue resistance through fully reversed fatigue tests on cellular specimens. The quality of the manufacturing process and the discrepancy between the actual measured cell parameters and the nominal CAD values were assessed through an extensive metrological analysis. The results of the metrological assessment allowed us to discuss the effect of manufacturing defects (porosity, surface roughness and geometrical inaccuracies) on the mechanical properties. Half of the specimens was subjected to a stress relief thermal treatment while the other half to Hot Isostatic Pressing (HIP), and we compared the effect of the treatments on porosity and on the mechanical properties. Fatigue strength seems to be highly dependent on the surface irregularities and notches introduced during the manufacturing process. In fully reversed fatigue tests, the high performances of stretching dominated structures compared to bending dominated structures are not found. In fact, with thicker struts, such structures proved to be more resistant, even if bending actions were present.

Cell shape effect evaluation of polyamide cellular structures

The paper describes an experimental investigation of regular open-cell cellular structures, where the influence of cell shape on cellular structure behavior under uniaxial compressive loading has been studied. Cellular structures with circular and quadratic cells have been manufactured with the laser sintered rapid prototyping technique using polyamide PA-12 as the base material. An advanced approach for Poisson’s ratio evaluation is proposed, which is based on the three-dimensional laser scanning technique. The experimental results have shown that the same layer-wise collapse mechanism, commonly observed in irregular open-cell structures, can be observed also in regular open-cell structures. The energy absorption characteristics show advantageous performance of cellular structures with circular cells in comparison to the quadratic cells.

Experimental Study of Open-Cell Cellular Structures with Elastic Filler Material

Open-cell cellular structures have a high potential for use in automotive, railway, ship and aerospace industry as crash energy absorbers. This paper focuses on the influence of the second phase filler material as a way to further increase the capability of cellular material energy absorption. The behaviour of ductile (aluminium alloy) and brittle (polymer) cellular structures with regular topology with and without the pore filler (silicon rubber) under quasi-static and dynamic compressive loading conditions has been experimentally studied and evaluated. The base material properties of the aluminium alloy and the polymer were obtained with separate experimental testing. The use of second phase filler material resulted in significant changes in cellular material behaviour. It was observed that the pore filler material increases the capability of energy absorption and furthermore improves and stabilises the response of a brittle cellular structures.

Behaviour of Cellular Structures under Impact Loading a Computational Study

New multiphysical computational models for simulation of regular open and closed-cell cellular structures behaviour under compressive impact loading are presented. The behaviour of cellular structures with fluid fillers under uniaxial impact loading and large deformations has been analyzed with the explicit nonlinear finite element code LS-DYNA. The behaviour of closed-cell cellular structure has been evaluated with the use of the representative volume element, where the influence of residual gas inside the closed pores has been studied. Open-cell cellular structure was modelled as a whole to properly account for considered fluid flow through the cells, which significantly influences macroscopic behaviour of cellular structure. The fluid has been modelled by applying a Smoothed Particle Hydrodynamics (SPH) method. Computational simulations showed that the base material has the highest influence on the behaviour of cellular structures under impact conditions. The increase of the relative density and strain rate results in increase of the cellular structure stiffness. Parametrical numerical simulations have also confirmed that filler influences the macroscopic behaviour of the cellular structures which depends on the loading type and the size of the cellular structure. In open-cell cellular structures with higher filler viscosity and higher relative density, increased impact energy absorption has been observed.

Behaviour of cellular structures with fluid fillers under impact loading

The paper describes experimental and computational testing of regular open-cell cellular structures behaviour under impact loading. Open-cell cellular specimens made of aluminium alloy and polymer were experimentally tested under quasi-static and dynamic compressive loading in order to evaluate the failure conditions and the strain rate sensitivity. Additionally, specimens with viscous fillers have been tested to determine the increase of the energy absorption due to filler effects. The tests have shown that brittle behaviour of the cellular structure due to sudden rupture of intercellular walls observed in quasi-static and dynamic tests is reduced by introduction of viscous filler, while at the same time the energy absorption is increased. The influence of fluid filler on open-cell cellular material behaviour under impact loading was further investigated with parametric computational simulations, where fully coupled interaction between the base material and the pore filler was considered. The explicit nonlinear finite element code ls-dyna was used for this purpose. Different failure criteria were evaluated to simulate the collapsing of intercellular walls and the failure mechanism of cellular structures in general. The new computational models and presented procedures enable determination of the optimal geometric and material parameters of cellular materials with viscous fillers for individual application demands. For example, the cellular structure stiffness and impact energy absorption through controlled deformation can be easily adapted to improve the efficiency of crash absorbers