Porosity Shape Research Articles

INFORMATION MODEL FOR SELECTING THE OPTIMAL SPATIAL FORM OF PARTS

A complex of interrelated methods and means of analysis, clustering, segmentation and classification of objects on images obtained by sensors of different physical nature (with the help of modern methods of radiography, computer and magnetic resonance imaging) is proposed, which will allow modeling the optimal form of a bone substitute with functional properties by CAD/CAM/CAE design methods, depending on the anatomical data, the nature and localization of the cavity bone defect, its size, load conditions and patterns of bone tissue neoplasm. Methods for making multi-criteria decisions have been developed, which will allow for their implementation for a wide range of optimization tasks of researching the correlation of the shape and size of porosity with indicators of the stress-deformed state of bone substitutes in order to maintain the structural integrity of the biomaterial in the process of regeneration of hard tissue.

Performance of normal-weight and lightweight 3D printed cementitious composites with recycled glass: Sorption and microstructural perspective

The development of sustainable mixtures has been a widely researched topic in the last decade, as the cement and concrete industries are among the most polluting sectors. Recycled materials can eliminate the need for extraction of natural materials through re-utilization of waste, reducing the environmental impact. To date, few studies have analyzed the effects of incorporating recycled glass aggregates on the water transport properties and microstructure of 3D printable mixtures.This study assesses the feasibility of incorporating recycled glass as a replacement for natural aggregate in 3D printable mixtures. For this purpose, three normal-weight and three lightweight mixtures containing 0, 50, and 100 vol.% of recycled glass aggregate as basalt aggregate replacement were evaluated in cast and printed samples. Expanded thermoplastic microspheres (ETM) were included to create the lightweight mixture composition. This experimental work evaluated the effects of incorporating recycled glass, ETM, and the impact of the printing process on the microstructure, sorption, and capillary water porosity (CWP).The printing process has proven to be an influential factor affecting the shape, size, and quantity of porosity. In addition, the printing process was demonstrated to be more influential on porosity formation than the inclusion of recycled glass or ETM. Incorporating recycled glass results in a slight decrease in the PHg porosity, more spherical pores, and lower anisotropic tendency. Furthermore, adding ETM has a filling effect, leading to a more compact microstructure.

Investigation and prediction of impact of aggregate size and shape on porosity and compressive strength of pervious concrete

ABSTRACT Pervious concrete is proven to environmentally benefit urban pavement construction. Optimising compaction energy evidently reduces uncertainty in the mass production of pervious concrete with uniform characteristics. The distribution of compaction energy in wet mix and rearrangement of binder-coated aggregate particles are affected by the size and shape of aggregates. This study analyses the impact of aggregate size and shape on porosity and compressive strength prediction from mix-design parameters. Aggregate-to-cement ratio (3, 4 and 5), compaction (0, 30 and 60 blows from standard Proctor rammer), aggregate sizes (5–12 mm, 12–18 mm and 18–25 mm) and aggregate shape (0, 200 and 1000 revolutions of milling in Los Angeles Abrasion Value) were used to cast a total number of 486 samples. Constituents were mixed in an electrically powered drum of capacity 96 L, for 20 min. Porosity was computed from constituent ratios (theoretical porosity) and apparent weight (measured porosity). The compressive strength of samples was recorded using a Universal Testing Machine. The measured porosity and theoretical porosity relationship was significantly affected by the shape of the aggregate and not by the size. Modified Ryshkewitch’s model predicted compressive strength from porosity, aggregate-to-cement ratio, compaction and aggregate size and shape with an accuracy of 0.92 (R2). Two of six arbitrary constants depended on aggregate shape and size.

Multiscale analysis of carbon/carbon composite pores based on X-ray computed tomography

Pore defects formed during the impregnation and carbonization of carbon/carbon (C/C) composites were investigated. X-ray computed tomography (XCT) was used to analyze the pore characteristics of C/C composites during liquid-phase impregnation and carbonization (LIC), highlighting the pore structural evolution from impregnation to carbonization and the resultant porous morphology. The porosity, pore location, pore size, and pore shape of the samples were subjected to quantitative analysis. At the micro-scale within the fiber bundles, the pores exhibited an ellipsoidal and elongated shape. In the impregnated samples, the pores were all isolated, and the ellipsoidal and elongated pores accounted for the majority of the pores, but their volume accounted for less than 9 % of the total pore volume. At the macro-scale, pores were predominantly distributed along the surfaces of fiber bundles and between layers, representing the primary form of pore distribution. Analysis of the carbonized samples showed that elongated pores within fiber bundles extended along both the fiber depth and radial directions. Macroscopic pores between fiber bundles and layers extended along the fiber bundle surfaces. The carbonization process caused the micro- and macro-pore spaces to interconnect to form connected pores, which accounted for 79 % of the total pore volume, while the ellipsoidal and elongated pores in the isolated pores accounted for less than 18 % of the total pore volume, forming a porous medium.

An experimental and numerical study of the influence of the additive manufacturing process in packing properties of particles: the printed shape matters

Investigations into the various properties of granular matter composed of particles with defined shapes have gained increasing attention. Additive manufacturing, with its freedom of shape and rapid prototyping capabilities, has significantly contributed to these studies. However, this technique may introduce defects in the manufactured particles, which can significantly affect the properties of granular materials. The extent of these defects on particles of different shapes is investigated here. Particles of various shapes (cube, octahedron, quatropod, stellated octahedron, tetrahedron, and tetrapod) were manufactured and subsequently imaged using micro-Computed Tomography. The surface roughness, solidity, and convexity of the particles were quantified. Discrete element simulations of granular bed porosity, utilizing both idealized and real particle shapes, were conducted with different surface mesh resolutions and frictional parameters. A clear influence of the manufacturing process on the packing properties of 3D printed particles was identified. This influence is not uniform across all shapes and is directly correlated with the particle convexity. For numerical simulations, a shape-dependent correction of particle density and surface characteristics are imperative for each shape under consideration, despite the fact that the particles were manufactured using the same technique and material.Graphic abstract

Numerical study on mechanical characteristics of gabion mixed media with discrete element method

Gabion mixed media is an important ecological protection method for preventing riverbank scouring. It is favored by engineers for its use of local materials, low carbon footprint, and environmental friendliness. However, the mechanical characteristics of gabion mixed media are closely related to the shape of the gabion mesh, the diameter of the gabion wire, and the type of internal media. Thus, its macroscopic properties are difficult to analyze. Therefore, this study adopts a discrete element method, Particle Flow Code 3D (PFC3D), to establish a numerical calculation model of gabion structures. This method analyzes the mechanical characteristics of gabion structures filled with spherical and oblate stones by considering porosity, mesh shape, filler size, and mesh size. Key results demonstrate that the bearing capacity and stability of a gabion structure filled with oblate stones is stronger than that of a gabion structure filled with spherical stones, with an increase of about 25 % in bearing capacity. Porosity and mesh shape have a considerable effect on the compressive strength of the gabion structure. Compared with high-porosity gabion structures, low-porosity gabion structures have a 50 %−65 % increase in compressive strength. Additionally, hexagonal mesh gabion structures exhibit better stability than quadrilateral mesh gabion structures and under axial loads, the hexagonal mesh is less prone to breakage. Increasing mesh size may cause smaller fillers to overflow, reducing the porosity of gabion structures and resulting in decreased compressive strength. The results of this study can provide a basis for estimating integrated parameters of gabion mixed media and determining slope stability.

Multiscale porosity characterization in additively manufactured polymer nanocomposites using micro-computed tomography

Extrusion-based additive manufacturing (AM) of polymer composites exhibits complex thermally driven phenomena that introduce severe discontinuities in the internal structure across length scales, especially voids or porosity. This study utilizes a high-throughput porosity characterization technique to analyze large datasets from numerous micro-computed tomography (μCT) scans to capture the influence of AM print parameters on the size, shape, and location of porosity across multiple print layers (up to a few cm) on fused granular fabrication (FGF) printers. The materials investigated include nanocomposite formulations based on commercially relevant nylon-12 and polyether ketone ketone (PEKK) materials comprising nano- or micro-sized fillers. The estimated global porosity follows an inverse linear correlation against the bulk density of the printed samples. Increasing the extrusion multiplier (EM) and the nozzle temperature while decreasing the print speeds reduces the global porosity. Outlier analyses (local porosity morphology) show that faster print speeds and higher extrusion rates result in long, slender inter-layer voids, while lower nozzle temperatures lead to large, symmetrical, inter-bead voids (at the bead junction). Lack of active chamber temperature increases inter-layer and intra-bead voids with a two-fold increase in global porosity. Overall, the micro filler-reinforced composites exhibit higher global porosity than nanofiller-reinforced composites, which is attributed to the increased mismatch in the thermal expansion coefficient between the filler and the polymers used in the study.

Behaviour of enzymatic soil stabilization at elevated temperatures using advanced micro structural investigations

ABSTRACT Soil moisture variation plays a key role in maintaining the engineering properties of soils. One of the main factors that impact the soil moisture content is the temperature, which has a strong impact to change the initial or design moisture and results in significant soil volume changes. This study aims to investigate the effects of temperature on the performance of enzymatically stabilised soils. The enzyme used in this study is Eko-soil and the soil used is clayey silt of low plasticity (ML). The mechanical behaviour was first assessed through the unconfined compression strength and weight measurements based on samples exposed to a series of operational temperatures. X-ray μCT tomography images were then used to assess the microstructure. Porosity, size and geometrical shape of the pores were analysed at elevated temperatures. Results revealed that the enzyme is effective in maintaining the initial pore structure under the tested temperature range.

A theoretical model for estimating the thermal conductivity of granular geomaterials with low porosity

The thermal conductivity has an important influence on the geotechnical and geoenvironmental engineering. Most existing thermal conductivity models appear to estimate the thermal conductivity of soils samples with large porosity, few of them were proposed to model the thermal conductivity of soil samples with low porosity. In this study, a theoretical model was proposed to estimate the thermal conductivity of unsaturated granular geomaterials with low porosity. Two parameters (i.e., ζ and β) were introduced. The parameter ζ can be applied to control porosity and solid particle shape, while the parameter β can be used to control water content. Mathematical comparison showed that the proposed thermal conductivity model fell within the Wiener bounds. The new model and five thermal conductivity models were evaluated with experimental data, showing that the new model accurately estimates the relationship between thermal conductivity and saturation for granular geomaterials with low porosity.

Ispitivanje zatezanja progresivnog oštećenja i loma u poroznim keramičkim kompozitnim materijalima pomoću proširenog metoda konačnih elemenata (XFEM)

Introduction/purpose: Porosity is a significant factor that causes voids to become trapped in materials during composite material fabrication. This study is dedicated to modelling fracture modes within highly stressed areas of an advanced SiC/Cf component at a macroscopic scale. Methods: The finite element method is used to analyze defects within composites, considering factors such as porosity size, shape, and tensile stress. The Monte Carlo method predicts the distribution function (F). Results: Three pores are distributed across the width of the material, which reduces the active cross-sectional area of the material and, consequently, leads to a significant reduction in strength. Overall, resistance tends to decrease, with a more noticeable drop. Conclusion: It is concluded how the form and the size affect the failure load, employing the Extended Finite Element Method (XFEM) to predict mode-I fracture behaviour. The porosity parameter significantly affects the durability of the structure. It is noted that the size of pores (ϕ) is a crucial component that affects the distribution function (F). The variability in this parameter substantially elevates the likelihood of plate failure and diminishes the longevity of a structure.

Thermo-hydraulic Analysis of Fluid Flowing Through Circular Pipe with Wire Mesh Inserts having Varying Mesh Porosity

The experimental investigation was made to analysis the rate of heat transfer of fluid flowing through a heat exchanger with varying wire-mesh porosity inserts. The Nusselt number (Nu), friction factor (f), and overall heat transfer rate (Q) were evaluated using experiments. Three different wire mesh inserts of square, hexagonal and diamond porosity were examined. The SS 316 stainless wire mesh with a porosity of 9 pores per inch (PPI) were inserted normal to the flow field with a pitch distance of 5 cm for each shape of wire mesh. The experiments were conducted on test rig with air as a working fluid for turbulent flow regime having Reynolds number ranging from 6,000 to 16,000. Experiments were performed on computerized test rig with heated air flowed in one direction through inner pipe and counter flow cold water flowing through the outer concentric pipe. The circular inner pipe of 40 cm long having 4 cm inner diameter (Di), and 3 mm thick was used for experimentation. The experimental results showed that Nusselt number (Nu) increases with decrease in friction factor (f) with increase in Reynolds number (Re). Also, it is observed that the hexagonal porosity shape of wire mesh insert provides higher material contact and gain more energy absorption from hot air resulted in improvement in heat transfer coefficient as compared to diagonal and square porosity shapes of wire mesh inserts, under similar operating conditions. The friction factor and pressure drop for square porosity shape of wire mesh insert is higher as compared to hexagonal and diagonal porosity shapes of wire mesh inserts respectively. This is due to the fact that square porosity wire mesh provides more obstruction in the flow field compared with hexagonal and diagonal porosity shapes of wire mesh inserts. The hexagonal porosity shape of wire mesh insert provides better option for heat exchange applications.

Fabrication of g-C3N4 decorated Au/Zn3(PO4)2 composites for remarkable H2 production under visible-light irradiation

In the present study, novel gold nanoparticles (Au NPs) loaded Zinc phosphate (Zn3(PO4)2)/graphitic carbon nitride (g-C3N4) nanocomposites were fabricated via a facile hydrothermal routes followed by calcination. Surfactants and capping agents were not required for this method. After the samples had been produced, they were examined using a number of electron microscopy and spectroscopic methods. The data showed that the spherical Zn3(PO4)2 particles that were coated on the g-C3N4 nanosheets had a good distribution of Au nanoparticles (NPs) on their surfaces. In comparison to Zn3(PO4)2 (461 μmol−1 h−1 of H2) and g-C3N4 (171 μmol−1 h−1 of H2), the optimized composite, 0.5 wt% Au/Zn3(PO4)2-gC3N4 (95–5), showed a remarkable production rate under visible light (1241 μmol−1 h−1 of H2). The highest performing composite was characterized using UV–visible, X-ray photoelectron spectra (XPS), Transmission electron microscope (TEM), N2 adsorption-desorption, time dependent photo-current study and Current-density–potential studies. Several events were identified as contributing to the photocatalyst's performance; for example, the effective heterojunction formation between g-C3N4 and Zn3(PO4)2 under Z-scheme dynamics led to visible-light photosensitization; new electronic hybrid states of the semiconductor band energies resulted from the porosity size and shape; and the Au NPs exhibited electronic trappingsites and co-catalytic effects. These enhancements to light harvesting and charge carrier separation allowed for greater activity to be powered by visible light.

The effect of organic matter amendments on soil surface stability in conventionally cultivated arable fields

AbstractIn this study, new and traditional organic wastes (green waste compost, farmyard manure (FYM), anaerobic digestate or straw) were ploughed into an arable field experiment at a range of rates (1–3 t C ha−1) and under spring and winter cropping rotations for 5 years. The stability of the soil surface structure (<5 cm) was assessed in Years 3, 4 and 5 to guide the use of organic wastes in arable field management. Aggregate stability was determined by immersing each soil sample in water (fast‐wetting test, relevance to summer storms) and measuring the size distribution of the aggregates (mean weight diameter, MWD). The MWD value was compared with the different classes of aggregate stability (very stable, stable, medium, unstable or very unstable) to classify each result. All the arable field samples were classified as unstable, and there were no significant differences (p > .05) in MWD after any treatment. Potentially, this approach is too imprecise to detect differences, so pore‐scale analyses using CT scanning were used. There were no significant differences in porosity or pore shape (features associated with microbial activity) between the control and organic waste treatments. The results contradicted published data from the Broadbalk experiment (established in 1843), which was the basis for this study, so its soils were studied to understand this discrepancy. Broadbalk soils were classified as unstable, including soils treated with annual FYM applications. Instead, we found a significant relationship between MWD and clay content and previous interpretations had not taken this variable (23%–39% clay content) texture into consideration. In conclusion, to achieve a stable soil surface structure, a 150% improvement in aggregate stability would be needed here and ploughing in organic wastes was not a successful management approach on these arable field experiments.

3D Printing of Bioactive Gel-like Double Emulsion into a Biocompatible Hierarchical Macroporous Self-Lubricating Scaffold for 3D Cell Culture.

The interconnected hierarchically porous structures are of key importance for potential applications as substrates for drug delivery, cell culture, and bioscaffolds, ensuring cell adhesion and sufficient diffusion of metabolites and nutrients. Here, encapsulation of a vitamin C-loaded gel-like double emulsion using a hydrophobic emulsifier and soy particles was performed to develop a bioactive bioink for 3D printing of highly porous scaffolds with enhanced cell biocompatibility. The produced double emulsions suggested a mechanical strength with the range of elastic moduli of soft tissues possessing a thixotropic feature and recoverable matrix. The outstanding flow behavior and viscoelasticity broaden the potential of gel-like double emulsion to engineer 3D scaffolds, in which 3D constructs showed a high level of porosity and excellent shape fidelity with antiwearing and self-lubricating properties. Investigation of cell viability and proliferation using fibroblasts (NIH-3T3) within vitamin C-loaded gel-like bioinks revealed that printed 3D scaffolds offered brilliant biocompatibility and cell adhesion. Compared to scaffolds without encapsulated vitamin C, 3D scaffolds containing vitamin C showed higher cell viability after 1 week of cell proliferation. This work represented a systematic investigation of hierarchical self-assembly in double emulsions and offered insights into mechanisms that control microstructure within supramolecular structures, which could be instructive for the design of advanced functional tissues.

Effect of Porosity and Pore Shape on the Mechanical and Biological Properties of Additively Manufactured Bone Scaffolds.

This study investigates the effect of porosity and pore shape on the biological and mechanical behavior of additively manufactured scaffolds for bone tissue engineering (BTE). Polylactic acid scaffolds with varying porosity levels (15-78%) and pore shapes, including regular (rectangular pores), gyroid, and diamond (triply periodic minimal surfaces) structures, are fabricated by fused filament fabrication. Murine-derived macrophages and human bone marrow-derived mesenchymal stromal cells (hBMSCs) are seeded onto the scaffolds. The compressive behavior and surface morphology of the scaffolds are characterized. The results show that scaffolds with 15%, 30%, and 45% porosity display the highest rate of macrophage and hBMSC growth. Gyroid and diamond scaffolds exhibit a higher rate of macrophage proliferation, while diamond scaffolds exhibit a higher rate of hBMSC proliferation. Additionally, gyroid and diamond scaffolds exhibit better compressive behavior compared to regular scaffolds. Of particular note, diamond scaffolds have the highest compressive modulus and strength. Surface morphology characterization indicates that the surface roughness of diamond and gyroid scaffolds is greater than that of regular scaffolds at the same porosity level, which is beneficial for cell attachment and proliferation. This study provides valuable insights into porosity and pore shape selection for additively manufactured scaffolds in BTE.

Modeling the relationship between mechanical yield stress and material geometry using convolutional neural networks

Machine learning methods can be used to predict the properties of materials from their structure. This can be particularly useful in cases where other standard methods for finding material properties are time and resources consuming to use on large sample spaces. In this work, we study the strength of α-quartz crystals with a porous layer created by simplex noise as the shape of porosity. We train a neural network to predict the yield stress of these systems under both shear and tensile deformation. Molecular dynamics simulations are used for a randomly selected sample of possible structures in order to generate the ground truth to be used as the training data. We employ deep convolutional neural networks (CNNs) which are commonly used when dealing with image or image-like data since the input data for the problem in hand are a binary 2D structure of the porous layer of the systems. The trained CNN can predict the yield stress of a system based on the geometry of that given system, with much higher precision compared to a baseline polynomial regression method. Saliency maps created with the trained model show that the model predictions are most sensitive to altering structures near high-stress regions, indicating that the model makes predictions based on reasonable physics.

Electrodialysis membrane desalination with diagonal membrane spacers: a review.

Electrodialysis desalination uses ion exchange membranes, membrane spacers, and conductors to remove salt from water. Membrane spacers, made of polymeric strands, reduce concentration polarization. These spacers have properties such as porosity and filament shape that affect their performance. One important property is the spacer-bulk attack angle. This study systematically reviews the characteristics of a 45° attack angle of spacers and its effects on concentration polarization and fluid dynamics. Membrane spacers in a channel create distinct flow fields and concentration profiles. When set at a 45° attack angle, spacers provide greater turbulence and mass-heat transfer than traditional spacers. This is because both the transverse and longitudinal filaments become diagonal in relation to the bulk flow direction. A lower attack angle (<45°) results in a lower pressure drop coupled with a decline in wakes and stream disruption because when the filaments are more parallel to the primary fluid direction, the poorer their affect. This research concludes that membrane spacers with a 45° spacer-bulk attack angle function optimally compared to other angles.

Determining the effect of porosities on the hydrogen adsorption capacity of 3D printed PEEK

In this investigation, as one of the most common polymer-based materials, polyether-ether-ketone (PEEK) was chosen to study its hydrogen adsorption capacity. The shape and size of porosities control the specific surface area and possible sites of hydrogen adsorption. Therefore, the FDM 3D printing method was utilized to fabricate the PEEK sample with different porosity sizes, and the effect of variation of the process parameters (nozzle temperature and nozzle speed) on the shape and size of porosities and finally, the hydrogen adsorption capacity was evaluated. The effect of the variation of the nozzle temperature on the heat distribution was simulated using COMSOL Multiphysics. The results of the heat temperature distribution exhibited that the shape of the porosities will be differed due to the solidification shrinkage caused by the temperature gradients in the middle areas of the 3D-printed PEEK samples, which was subsequently confirmed by optical microscopy and X-ray Computed Tomography (XCT). Porosities can be classified into three main groups including mesopores, mesopores and macropores. Additionally, 3D printed parts have the porous structure and by designing a porous structure by CAD software, the formation of the macropores and subsequently meso-and micropores is passivated, which can be detected through the XCT results. Consequently, these pores increased the surface area and provide more site for hydrogen adsorption. XCT was carried out, and the results showed the formation of the closed pores, which was decreased by increasing the nozzle temperature due to the presence of the melted filament from 0.64 to 0.19%. The hydrogen adsorption capacity was studied through electrochemical analysis methods including cyclic voltammetry, charge/discharge, and electrochemical impedance spectroscopy. Results showed that the sample was printed with a nozzle temperature of 375 °C and nozzle speed of 30 mm s−1, illustrating the highest electrochemical hydrogen adsorption capacity of 2.66 mAh.g−1, which can be related to the activation of the capillary force and new available sites in the interface of the electrolyte and 3D-printed electrode.

Osteogenic differentiation of 3D-printed porous tantalum with nano-topographic modification for repairing craniofacial bone defects.

Introduction: Congenital or acquired bone defects in the oral and cranio-maxillofacial (OCMF) regions can seriously affect the normal function and facial appearance of patients, and cause great harm to their physical and mental health. To achieve good bone defect repair results, the prosthesis requires good osteogenic ability, appropriate porosity, and precise three-dimensional shape. Tantalum (Ta) has better mechanical properties, osteogenic ability, and microstructure compared to Ti6Al4V, and has become a potential alternative material for bone repair. The bones in the OCMF region have unique shapes, and 3D printing technology is the preferred method for manufacturing personalized prosthesis with complex shapes and structures. The surface characteristics of materials, such as surface morphology, can affect the biological behavior of cells. Among them, nano-topographic surface modification can endow materials with unique surface properties such as wettability and large surface area, enhancing the adhesion of osteoblasts and thereby enhancing their osteogenic ability. Methods: This study used 3D-printed porous tantalum scaffolds, and constructed nano-topographic surface through hydrothermal treatment. Its osteogenic ability was verified through a series of in vitro and in vivo experiments. Results: The porous tantalum modified by nano-topographic surface can promote the proliferation and osteogenic differentiation of BMSCs, and accelerate the formation of new bone in the Angle of the mandible bone defect of rabbits. Discussion: It can be seen that 3D-printed nano-topographic surface modified porous tantalum has broad application prospects in the repair of OCMF bone defects.

Metal foam reinforced phase change material energy storage device: A collaborative optimization strategy for porosity and container shape

Latent heat thermal energy storage (LHTES) is often employed in solar energy storage systems to improve efficiency. This method uses phase change materials (PCM) as heat storage medium, often augmented with metal foam to optimize heat transfer. In this paper, we introduce a novel approach of altering the container shape to enhance the heat storage effectiveness. LHTES tank with different coning coefficients (C) is designed by reducing the hard-to-melt bottom region. Based on the finite volume, volume averaging, and enthalpy porosity method, the transformation process of a simplified two-dimensional model of the LHTES tank is numerically simulated. Analysis focuses on the evolution of liquid-solid interface, liquid fraction, temperature field, and heat storage performance. The results indicate that the bottom region area enhances the heat storage performance when C < 0.375, whereas for C ≥ 0.375, it hinders heat transfer. When the porosity is 0.93, the newly deformed LHTES tank demonstrates a reduction of up to 6.2% in melting time compared with the basic model. Additionally, it achieves 98% of the basic thermal energy storage. Furthermore, metal foams with varying porosity are analyzed, and a cooperative optimization matching strategy between porosity and shape is obtained. By reducing the porosity to 0.87, the melting time can achieve a 61% reduction at C = 0.125. This study is expected to provide new insights and references for optimizing the design of LHTES devices.