Porous Plastic Research Articles

Recovered Foam Impact Absorption Systems

The use of foam materials in environments where they come into contact with individuals often results in deterioration, necessitating periodic replacements to maintain safety and hygiene standards. Foam, a lightweight, porous plastic formed by aggregated bubbles, possesses excellent impact-absorbing properties; however, its inherent porosity and susceptibility to wear present challenges. This project aims to develop a technological application for repurposing spent polyurethane (PU) foam from leisure facilities into effective impact absorption systems. By focusing on the reuse of deteriorated foam materials, this initiative seeks to minimize environmental impact while leveraging their beneficial technical characteristics. Addressing issues related to foam degradation, this project endeavors to create sustainable solutions by reintegrating spent foam into new systems. This innovative approach promotes sustainability while enhancing safety through the provision of high-quality, impact-resistant elements. Ultimately, this work aims to contribute to environmental conservation and the advancement of effective impact protection measures in leisure facilities.

Influence of textural variability on plastic response of porous crystal embedded in polycrystalline aggregate: A crystal plasticity study

Damage evolution in polycrystalline aggregates is complicated by the intricate interplay of crystallographic orientation of the porous grain and the surrounding anisotropic matrix. Therefore, formulation of design rules and damage models for polycrystalline materials proves daunting due to relative lack of thorough understanding of the underlying heterogeneity at the mesoscale. This work explores the orientation dependent void growth in a porous crystal embedded in an anisotropic polycrystalline matrix with different initial textures. Polycrystalline face-centered cubic based aggregate is simulated within the framework of crystal plasticity finite element method. Porosity is first modeled in the form of a single pre-existing spherical void in the central grain of the randomly oriented polycrystal. One-hundred crystallographic orientations of the central grain in three-dimensional Euler space are analyzed to reveal the orientation dependent trends of the porous grain. To account for textural variability, the analysis is repeated for polycrystals exhibiting preferred textures like Cube, Brass, Copper and Goss. In this manner, interesting orientation dependent trends in basic tenets of void growth like yield strength, coalescence strain and porosity evolution are unraveled across various polycrystalline textures. To account for spatial heterogeneity as well, porosity in the central grain is then re-distributed and the aforementioned analysis is repeated for all the crystallographic orientations of the central grain embedded in polycrystals with different textures. Owing to the large amount of data thus generated, statistical analysis is invoked to identify stimulating trends and key statistical variables governing the strength and toughness. Consequently, a statistical void growth model is also presented by assessing the CP simulation results and identifying suitable distribution function governing the growth of voids in polycrystals. The modeling framework is expected to inform porous plasticity models aimed at capturing damage evolution in porous grains embedded in polycrystalline materials exhibiting topological and crystallographic anisotropy.

The Structural and Mechanical Properties of Al2O3-Ni Composites Obtained by Magnetic Field-Assisted Centrifugal Slip Casting.

This study investigates the influence of a magnetic field on the microstructure and properties of Al2O3-Ni composites fabricated via centrifugal slip casting at 1500 rpm. Al2O3 and Ni powders were combined with water and deflocculants, homogenized, and then cast into a porous plaster mold surrounded by Nd-Fe-B magnets. The resulting composites, sintered in a reducing atmosphere, exhibited a three-zone structure with varying Ni content due to the combined effects of the magnetic field and centrifugal force. SEM, EDX, and XRD analyses confirmed the distribution and composition of the phases. Hardness tests revealed the highest values at the outermost zone, with a gradual decrease toward the inner zones. Compression tests employing digital image correlation revealed high internal stresses and a significant improvement in compressive strength compared to non-magnetic field methods. This study confirms that magnetic field-assisted centrifugal slip casting significantly enhances the structural, hardness, and compressive strength properties of Al2O3-Ni composites, indicating promising potential for advanced applications.

Modelling the effects of void swelling and spatial heterogeneity on the fracture of metallic materials by crystal plasticity

To theoretically analyse how void swelling and spatial heterogeneity impact the fracture behaviour of metallic materials, a coupled porous crystal plasticity framework has been developed. The proposed framework is then applied to analyse the fracture behaviour of metallic materials under different swelling conditions and types of spatial heterogeneity. It is revealed that at low porosity, the spatial heterogeneity of voids will have limited influence on the fracture behaviour of the material. However, at high porosity, owing to void swelling, a concentrated distribution of voids near grain boundaries can lead to a strong deformation localization, which can be seen as an indicator of possible quasi-brittle fracture. It is further discovered that the inner pressure of the voids tends to reduce the yield stress of the material and promote localized plastic deformation. As a result, such pressure will enhance the impact of concentrated distribution of voids, which can lead to further embrittlement of the material. The present study reveals the key role of void swelling and spatial heterogeneity in regulating the fracture behaviour of metallic materials, a step towards a better understanding over the failure mechanisms of metallic materials under extreme conditions.

Periodical alternation between precipitation and dissolution of camphor solid film on an ethanol solution.

Rhythmic behaviors are generally observed in nonlinear chemical reactions such as the Belousov-Zhabotinsky reaction and enzymatic reactions. Similarly, a simple phase change can also lead to rhythmic behavior. It has been reported previously that camphor solid films alternate between generation and disappearance on ethanol (EtOH) solution, and a phenomenological mechanism has been suggested for this. The evaporation of EtOH decreases the temperature on the surface of the solution via vaporization heat and induces precipitation in the camphor solid film. At this time, the film prevents evaporation, and thus, the surface temperature increases due to thermal diffusion from the atmosphere, resulting in dissolution of the solid film. To verify the previously suggested phenomenological mechanism, we controlled the evaporation rate of EtOH using a porous plastic cover. As a result, the period of oscillation increased with decreasing pore diameter, and finally, the oscillation did not occur without pore in the cover, where the camphor solid film was not observed. Additionally, a new mathematical model was proposed, and the numerical calculations agreed well with experimental observations. Linear stability and bifurcation analyses revealed the detailed mechanism of this phenomenon, which agreed well with the phenomenological explanation mentioned above.

Advancing into Millimeter Wavelengths for IoT: Multibeam Modified Planar Luneburg Lens Antenna with Porous Plastic Material

This paper introduces an innovative antenna design utilizing a cylindrical dielectric Luneburg lens tailored for 60 GHz Internet of Things (IoT) applications. To optimize V-band communications, the permittivity of the dielectric medium is strategically adjusted by precisely manipulating the physical porosity. In IoT scenarios, employing a microstrip dipole antenna with an emission pattern resembling cos10 enhances beam illumination within the waveguide, thereby improving communication and sensing capabilities. The refractive index gradient of the Luneburg lens is modified by manipulating the material’s porosity using air holes, prioritizing signal accuracy and reliability. Fabricated with polyimide using 3D printing, the proposed antenna features a slim profile ideal for IoT applications with space constraints, such as smart homes and unmanned aerial vehicles. Its innovative design is underscored by selective laser sintering (SLS), offering scalable and cost-effective production. Measured results demonstrate the antenna’s exceptional performance, surpassing IoT deployment standards. This pioneering approach to designing multibeam Luneburg lens antennas, leveraging 3D printing’s porosity control for millimeter-wave applications, represents a significant advancement in antenna technology with scanning ability between −67 and 67 degrees. It paves the way for enhanced IoT infrastructure characterized by advanced sensing capabilities and improved connectivity.

Void growth and coalescence in sigmoidal hardening porous plastic solids under tensile and shear loading

Void growth and coalescence in sigmoidal hardening porous plastic solids under tensile and shear loading

Moving from theory to application: Evaluating the numerical implementation of void shape effects and damage delocalization in the modeling of ductile fracture in porous plastic metals

In this paper, we present a robust exploration of the Gologanu–Leblond–Devaux (GLD) model, an advanced iteration of the Gurson model, designed to predict ductile fractures in porous metals. Going beyond the limits of the original Gurson model, the GLD model accounts for cavity shape effects and non-local strain localization, marking a significant leap in fracture mechanics. We also present a comprehensive exposition of the GLD model and its non-local extension, establishing their compatibility with the concept of GSMs. Notably, we emphasize the uniqueness of solutions in the numerical implementation, underlining the imperative need for a meticulously devised mixed implicit/explicit algorithm. Furthermore, we set out to validate the GLD model through rigorous comparisons of our numerical simulations with experimental data. Employing a damage delocalization approach rooted in the natural logarithm of porosity, our study provides compelling evidence of the model’s performance. This approach mitigates issues observed with the original porosity rate, preventing excessive smoothing of porosity and maintaining the fidelity of stress–strain curves. In addition, we gave a profound theoretical elucidation of this phenomenon via Fourier’s analysis of porosity rate. Through this work, we not only enhance our understanding of ductile fracture behavior but also establish a robust numerical framework for its predictive modeling. The GLD model emerges as a powerful tool for the accurate analysis and prediction of fracture phenomena in porous materials, further advancing the field of materials science and engineering.

A gel-coated air-liquid-interface culture system with tunable substrate stiffness matching healthy and diseased lung tissues.

Since its invention in the late 1980s, the air-liquid-interface (ALI) culture system has been the standard in vitro model for studying human airway biology and pulmonary diseases. However, in a conventional ALI system, cells are cultured on a porous plastic membrane that is much stiffer than human airway tissues. Here, we develop a gel-ALI culture system by simply coating the plastic membrane with a thin layer of hydrogel with tunable stiffness matching that of healthy and fibrotic airway tissues. We determine the optimum gel thickness that does not impair the transport of nutrients and biomolecules essential to cell growth. We show that the gel-ALI system allows human bronchial epithelial cells (HBECs) to proliferate and differentiate into pseudostratified epithelium. Furthermore, we discover that HBECs migrate significantly faster on hydrogel substrates with stiffness matching that of fibrotic lung tissues, highlighting the importance of mechanical cues in human airway remodeling. The developed gel-ALI system provides a facile approach to studying the effects of mechanical cues in human airway biology and in modeling pulmonary diseases.NEW & NOTEWORTHY In a conventional ALI system, cells are cultured on a plastic membrane that is much stiffer than human airway tissues. We develop a gel-ALI system by coating the plastic membrane with a thin layer of hydrogel with tunable stiffness matching that of healthy and fibrotic airway tissues. We discover that human bronchial epithelial cells migrate significantly faster on hydrogel substrates with pathological stiffness, highlighting the importance of mechanical cues in human airway remodeling.

A homogenization-based model of the Gurson type for porous metals comprising randomly oriented spheroidal voids

In this work, we propose a new fully explicit isotropic, rate-independent, elasto-plastic model for porous materials comprising a random with uniform probability, isotropic distribution of randomly oriented spheroidal voids of the same shape. The proposed model is based on earlier homogenization estimates that use a linear comparison composite theory. The resulting expressions exhibit the simplicity of the well known Gurson model and, thus, its numerical implementation in a finite element code is straightforward. To assess the accuracy of the analytical model, we carry out detailed finite-strain, three-dimensional finite element (FE) simulations of representative volume elements (RVEs) with the corresponding microstructures. Proper minimal parameter calibration of the model leads to fairly accurate agreement of the analytical predictions with the corresponding FE average stresses and porosity evolution. We show, both analytically and numerically, that the initial aspect ratio of the voids has a significant effect on the homogenized yield surface of the porous material leading to extremely soft responses for flat oblate voids (e.g. aspect ratio less than 0.5) especially at large triaxialities. Finally, after numerical implementation of the model in a commercial finite element code (ABAQUS), we solve the industrially important problem of hole expansion and comment on the role of porous compressible plasticity versus classical incompressible plasticity.

Моделювання процесів виготовлення тонкостінних втулок з поруватих заготовок з використанням прямого видавлювання та радіального ущільнення

The deformation process of powder materials thin-walled bushings manufacture was investigated by computer modeling. Two shape formation bushings schemeswere considered (direct extrusion and radial compaction).A continuum approach was used to create a modeling method. The method is based on rheological models of porous body plastic deformation and the finite element method. The accepted material rheological model allows describing the deformation of both powder and porous blanks. It takes into account the different resistance of these materials in tension and compression. Modeling of the deformation process was carried out in stages, using the method of successive loads. The elastic stresses were determined, the plastic potential was calculated and, if it was necessary, the stresses and material parameters of the model were corrected at each load step. The porosity value is reach maximum in blank and area, that is free from the loads, and the accumulated deformation is reachminimum in direct extrusion. The effect of back pressure leads to a more uniform distribution of these parameters, a decrease in porosity and an increase in the accumulated deformation of the solid phase. During radial compaction of thin-walled bushings, deformation of the material occurs locally. Porosity in the product section increases with increasing radius. Increasing the number of technological transitions with a gradual increase in the forming tool diameter reduces the uneven distribution of residual porosity and its value. However, the unevenness of the porosity distribution over the radius remains. In the process of radial compaction, a burr is formed on the ends of the product. The burr can be reduced by changing the initial shape of the blank. The process of direct extrusion allows obtaining more uniform distribution of residual porosity and accumulated plastic deformation of product material. However, this technological process requires the higher loads application, which leads to less stability of the tool. The radial compaction method (which characterized by local deformation) requires not high loads and allows not powerful equipment using. However, the distribution of residual porosity over the radius of the bushing is uneven. Keywords: plasticity theory, powder materials, computer modeling, finite element method, stress-strain state, porosity distribution.

The seasonality of the concentration of endocrine phenolic compounds in the matter attached to the surface of microplastics

Rapid biofilm formation on microplastic (MP) surfaces in marine environments and the tendency of hydrophobic pollutants to bioaccumulate may increase the exposure of organisms to ingested plastics and transport pollutants far from their sources. The role of the matter attached to MPs (MaM) in the interactions between MPs and other pollutants in marine environments is poorly understood. This paper studies pollutant sorption in MaM for three phenolic endocrine-disrupting chemicals (EDCs): bisphenol A (BPA), 4-tert-octylphenol (4-t-OP), and 4-nonylphenol (4-NP). Polypropylene (PP), expanded polystyrene (EPS), and polylactide (PLA) MPs were exposed to an environment conducive to biofouling (Vistula Lagoon, Baltic Sea) for four weeks in summer, spring, and winter. The concentrations of EDCs in MaM and the suspended particulate matter (SPM) were similar and were 2–3 orders of magnitude higher than those in water and sediment. The type and morphology of the polymers were less significant for determining the concentrations of EDCs in MaM than the season. The concentrations were higher in the growing season than in winter. EDCs increased linearly with the increase in particulate organic carbon. The relationships between organic carbon partition coefficients and octanol/water partition coefficients indicate that hydrophobic partitioning into organic matter was the dominant mechanism of 4-t-OP and 4-NP binding in MaM and in SPM. For BPA, additional sorption mechanisms seem to be significant. In addition to the direct sorption from ambient water, the binding of phytoplankton-derived particles, most probably via attachment to extracellular polymeric substances, appears to be a source of EDCs in MPs. Rough estimates showed that the largest load of particulate matter and EDCs was attached to expanded polystyrene. This study suggests that the potential negative impacts of MPs on the environment are seasonal and that low-density porous plastics can be particularly effective carriers of large EDC loads.

Unveiling the Strain Rate Sensitivity of G18NiCrMo3-6 CAST Steel in Tension/Compression Asymmetry

This research was devoted to unveiling the strain rate sensitivity (SRS) of G18NiCrMo3-6 cast steel in tension/compression asymmetry. For that purpose, detailed mechanical characterization tests were conducted providing a process window covering quasi-static and medium strain rate regimes (0.001, 0.1, 10 [s−1]) in tension and compression states. Through this experimental effort, the SRS of the material could be extracted by a function of strain and the strain rate which enabled us to create a mathematical expression to easily be implemented as a state variable for constitutive material modeling. Finally, a pressure- and rate-dependent constitutive material model on the basis of the Cocks’89 yield locus definition was created using a subroutine (UMAT) file and the material parameters were verified with respect to the experimental data. The UMAT file also takes into account the tension/compression asymmetry in yielding to handle the effect of the porous media plasticity concept. The predictions of the proposed material model are in line with the experimental outputs.

Electromagnetic Properties of 3D Printed Conductive Porous Plastics at Extremely High Frequency

Electromagnetic Properties of 3D Printed Conductive Porous Plastics at Extremely High Frequency

Size-dependent yield criterion for single crystals containing spherical voids

A micromechanics-based yield criterion is derived for a porous single crystal containing a random distribution of spherical voids, using homogenization and limit analysis of a hollow spherical representative volume element obeying a strain gradient crystal plasticity model. The criterion captures the effect of plastic anisotropy due to crystallographic slip on a set of discrete slip systems, as well as the void size dependence of yielding. The yield criterion is formally similar to the well known Gurson model for isotropic porous materials, and reduces to existing results in the literature in the limiting case of large void sizes relative to the length scale in the gradient plasticity model. The yield criterion is validated by comparison with rigorous upper bound yield loci obtained using a numerical limit analysis procedure. Predictions for the size dependence of void growth are obtained by integrating the porous plasticity model, and shown to be consistent with the observations from lower scale discrete dislocation dynamics simulations. The loading path dependence of void growth in the size-independent limit are compared with finite element simulations of void growth in a single crystal using the unit cell model.

“Implicit” vs “Explicit” gradient plasticity models: Do they always remove mesh dependence in softening materials?

Finite element quasi-static solutions of rate-independent softening plasticity models are known to depend on the mesh size (i.e., are unreliable) due to loss of ellipticity of the governing partial differential equations, which allows for the development of non-smooth solutions, such as shear bands of zero thickness. A “regularization” scheme that has been proposed is the use of “non-local” (Bažant et al., 1984) or “strain-gradient” theories (Aifantis, 1984). We examine in detail the families of “explicit” and “implicit” gradient plasticity models and show that use of such theories does not always eliminate mesh dependence of finite element solutions in rate-independent softening materials. Depending on the value of the non-local hardening modulus, the mathematical problem may still lose ellipticity and allow for the development of solutions with discontinuous spatial velocity gradients, which are responsible for the mesh dependence of numerical solutions. As an example, a rate-independent “implicit” gradient version of the von Mises yield condition with the associated flow rule is implemented in ABAQUS, and the formation of shear bands in plane strain tension is analyzed numerically; it is shown that, unless the material parameters in the non-local model are such that ellipticity is retained, the finite element solutions depend on the mesh size. The example of isotropic porous metal plasticity with a hardening matrix material is considered (e.g., the Gurson (1977) model); it is shown that regularization is achieved if an implicit non-local model is used, in which the local porosity f is replaced by its non-local (neighborhood average) counterpart f̄ in the yield condition. In all non-local plasticity models, dimensional consistency requires the introduction of one or more “material lengths” ℓi, which multiply the additional terms with the higher-order spatial derivatives introduced by the non-local models. The boundary layers associated with the singular perturbation problem when the material lengths ℓi→0 are examined. A linear stability analysis is carried out to study the stability of homogeneous problems under small harmonic perturbations; it is shown that the stability range of the non-local models is always larger than that of the corresponding local models.

Modelling of ductile failure in materials with heterogeneous particle structure using localization analysis

In this study, we evaluate the use of strain localization analysis based on the imperfection band approach to model the effect of heterogeneous particle distribution on the ductile failure of structural metallic materials. To this end, tensile tests are performed on smooth and notched samples made of aluminium alloy AA6110 with an equiaxed grain structure and an inhomogeneous distribution of the constituent particles. The constituent particles are assumed to be the main contributors to the ductile failure of the alloy. By varying the heat treatment of the alloy, three different materials are considered with different strength, work hardening, and ductility, while the grain structure and constituent particle distribution are unaltered. Finite element simulations of the tension tests are conducted using both metal and porous plasticity models and the stress–strain histories of the elements in the minimum section of the specimen are used in strain localization analyses. In these analyses, ductile failure is assumed to occur when the strain rate inside a thin, planar imperfection band becomes infinite. The imperfection band is modelled with porous plasticity, using either a higher initial porosity than in the bulk material or by adding void nucleation. It is found that the ductility of the materials is most accurately captured by modelling the imperfection band by stress-enhanced nucleation.

A non-local GTN model with two length scales – Application to ductile failure in a wide range of stress triaxiality

A non-local extension of the shear-modified Gurson model for porous plasticity is proposed, which is capable of preventing spurious strain localization and suitable for predicting crack initiation and growth under general loading conditions. In the extended model, the progression of shear failure is separated from flat dimple rupture by the assumption that these failure mechanisms are characterized by a deviatoric and a dilatational material length parameter, respectively. The two length parameters are introduced through a delocalization process based on the non-local integral approach evaluated on the current configuration. A comprehensive numerical investigation is conducted to disclose the influence of these length parameters. For this purpose, five different specimen geometries are considered covering a wide range of stress triaxiality including pure shear. It is observed that separation of the length parameters is essential for predicting crack branching driven by shear localization, e.g., the flat dimple-to-shear failure transition of a crack that approaches and penetrates a free surface.

Ultra-Low Cycle Fatigue Life Prediction Model—A Review

This article is a review of models for predicting ultra-low cycle fatigue life. In the article, the life prediction models are divided into three types: (1) microscopic ductile fracture models based on cavity growth and cavity merger; (2) fracture models based on porous plasticity; and (3) ductile fracture models based on continuum damage mechanics. Furthermore, the article provides a critical assessment of the current state of research on ultra-low cycle fatigue life prediction models, highlighting the limitations and challenges faced by each model type. Ultimately, this review aims to provide a comprehensive overview of the different models available for predicting ultra-low cycle fatigue life and to guide future research in this important area of materials science and engineering.

A numerical study on the effect of porosity distribution on ductile failure using size-dependent finite element-based representative volume elements

In this work, we use the size-dependent Monchiet-Bonnet porous plasticity model to study the influence of void size distribution on ductile fracture. The size effect implies that the void growth depends on the material intrinsic length scale in addition to the plastic deformation and stress state of the material, and smaller voids grow more slowly than larger voids. Finite element-based representative volume elements (RVEs) are built where each element is given an initial porosity and initial void size according to the specified void size distribution. The RVEs are loaded plastically to fracture under different stress states to study the influence of the void size distribution on ductility. The results show that heterogeneity can trigger a macroscopic failure mode caused by localized plastic flow. The onset of localized plastic flow is sensitive to the material heterogeneity while the stress-strain response up to the point of localization is not.