Analysis of density-dependent bead and cell structure of expanded polypropylene bead foams from X-ray computed tomography of different resolution

Closed-cell bead foams with their hierarchical geometrical structure are a challenge for statistical reconstruction and finite element modelling. For the purpose of providing the fundamental micro- and meso-structural descriptors - wall thickness, cell as well as bead volume and sphericity - of expanded polypropylene bead foams of different density, 3D-images from X-ray computed tomography are analyzed. A detailed description of development and application of an image analysis methodology for the determination of feature distributions from CT-scans of different level of detail is provided. The methods are based on off-the-shelf algorithms provided by the open-source package distribution FIJI. It should be highlighted, that beside essential methods such as thresholding, euclidean distance and watershed transformation here the Trainable WEKA segmentation is applied for separating material phases in the images. Although the methods elaborated are generally very case sensitive, the reader benefits from the validation strategies applied, so that development of individual methods into the direction of reliability, repeatability and automation is supported.

Characterization of microstructures of SAN foam core using micro-computed tomography

In this study, the microstructure of a SAN foam was imaged using a micro-CT scanner. Through image processing and analysis, variations in density, cell wall thickness and cell size in the foam were quantitatively explored. It is found that cells in the foam are not elongated in the thickness (or rise) direction of foam sheets, but rather equiaxed. Cell walls in the foam are significantly straight. Density, cell size and cell wall thickness all vary along the thickness direction of foam sheets. The low density in the vicinity of one face of foam sheets leads to low compressive stiffness and strength, resulting in the strain localization observed in our previous compressive tests. For M80, large open cells on the top face of foam sheets are likely to buckle in compressive tests, therefore being another potential contributor to the strain localization as well. The average cell wall thickness measured from 2D slice images is around 1.4 times that measured from 3D images, and the average cell size measured from 2D slice images is about 13.8% smaller than that measured from 3D images. The dispersions of cell wall thickness measured from 2D slice images are 1.16–1.20 times those measured from 3D images. The dispersions of cell size measured from 2D slice images are 1.12–1.36 times those measured from 3D images.

Random equilateral Kelvin open-cell foam microstructures: Cross-section shapes, compressive behavior, and isotropic characteristics

Representative volume elements of random equilateral Kelvin open-cell microstructures were modeled for the open-cell foam. We adopted the periodic boundary conditions developed in our previous research. The quasistatic compression properties of the representative volume elements in random Kelvin open-cell aluminum foam samples, both with different relative densities and different cross-sections of the beams in the structures were investigated. The results show that the features of the stress–strain curves in the representative volume elements with different relative densities and different cross-sections were similar, and the relationships between the yield strengths and relative densities of representative volume elements with four different cross-sections all agreed well with the quadratic power function. Among the representative volume elements with four different cross-sections, the yield strengths of the representative volume elements with a Plateau border cross-section were significantly larger than in representative volume elements with other cross-sections, while the yield strengths of representative volume elements with circular cross-sections were smaller than in representative volume elements with other cross-sections. This indicates that the simulation results of the compression strengths for open-cell foam in which the representative volume elements with circular cross-sections were employed are significantly smaller than their actual values. The main reason for this is that the moments of inertia in the Plateau border cross-sections are significantly greater than in the circular cross-sections of the same area. Our investigation results revealed that the compression responses of the representative volume elements for random equilateral Kelvin open-cell microstructures demonstrate isotropic behavior on the xoy plane, the yoz plane, and the xoz plane.