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High expansion foam (Hi-Ex) is a firefighting technology that has been widely used for fire suppression in underground locations. Hi-ex foam can be applied remotely through boreholes from the surface reducing firefighter exposure to fires. Despite the experimental studies that have been carried out there are still some uncertainties about foam behavior in underground locations. For this reason, the main objective of this thesis was to estimate Hi-Ex foam flow behavior in different underground configurations using computational fluid dynamics (CFD) simulations. An experimental apparatus was built to study the foam rheology in order to determine the rheological model parameters to simulate foam as a continuous Non-Newtonian fluid. Furthermore, numerical and experimental results of Hi-Ex foam flowing in a pipe were compared with the objective of validating numerical results. Results of this study show that Hi-Ex foam with an expansion ratio between 1:250 and 1:1280 behaves as a shear thinning fluid represented by the power law model. Numerical simulations results were between 0.06% and 14% of experimental results for Reynolds numbers between 200 and 1700. Finally, numerical simulations of Hi-Ex foam in different mine entry slopes were carried out and compared with qualitative results of prior field work. This work generates some of the necessary numerical parameters for the simulation of Hi-Ex foam flow in mines. Furthermore, results of this work and the methodology used can allow for improved predictions of foam flow in in underground mine fires, while improving safety for mine workers / Master of Science

Foam flow in porous media is important for many industrial operations such as enhanced oil recovery, remediation of contaminated aquifers and CO2 sequestration. The application of foam in these processes is due to its unique ability to reduce gas mobility and to divert gas to low permeability zones in porous media which otherwise would not be reached. To achieve optimum success with foam as a displacing fluid in oil recovery and remediation operations, it is essential to understand how different parameters influence foam flow in porous media. In this thesis, a variety of experimental techniques were used to study foam stability, foam rheology as well as the dynamics and patterns of oil displacement by foam under different boundary conditions such as surfactant formulation, oil type, foam quality (gas fraction) and porous media geometry. Bulk scale studies showed that foam stability was surfactant and oil dependant such that decreasing oil carbon number and viscosity decreased the stability of foam. However, no meaningful correlation was found between foam stability at bulk scale and the efficiency of oil displacement in porous media for the various surfactants studied in this work. Additionally, our results show that foams consisting of smaller bubbles do not necessarily correspond to higher apparent viscosity as the foam quality is also crucial. For the same foam quality decreasing bubble size resulted in higher apparent viscosity. Although in theory a higher apparent viscosity (i.e. higher foam quality) would be ideal for displacement purposes, increasing foam quality resulted in less stable foam in porous media due to formation of thin films which were less stable in the presence of oil. The effect of pore geometry on foam generation and oil displacement has also been investigated. Our findings provide new insights about the physics and complex dynamics of foam flow in porous media.

Les mousses polymères trouvent de nombreuses applications industrielles en tant qu’isolants thermiques, matériaux de structuration ou atténuateurs de choc. En effet, il s’agit de matériaux légers, possédant un excellent rapport masse / rigidité, et demandant de faibles coûts de production.Une des applications envisagées par le CEA est la protection de structures face à des chargements mécaniques générés lors d’irradiations laser ou lors d’impacts de débris micrométriques.L’objectif principal de cette thèse est d’évaluer la capacité d’atténuation d’une mousse expansée en polyuréthane rigide et d’une mousse syntactique à matrice époxy face à des sollicitations dynamiques extrêmement rapides (> 106 s−1) et intenses (> 10 GPa). Des essais quasi-statiques de compression / décompression et des expériences dynamiques ont ont été réalisés pour analyser le comportement de ces deux mousses pour des vitesses de déformation allant de 10−3 à 106 s−1. L’analyse des résultats expérimentaux montre que ces mousses polymères ont une phase de comportement élastique suivie d’une phase de compaction conduisant à des déformations irréversibles importantes. Les seuils de compaction sont estimés à 9 MPa pour la mousse polyuréthane et 30 MPa pour la mousse époxy en régime quasi-statique, et à 21 MPa pour la mousse polyuréthane et 72 MPa pour la mousse époxy lorsque la vitesse de déformation dépasse 104 s−1. Deux modèles physico-numériques sont développés pour représenter le comportement macroscopique de ces mousses à de telles vitesses de déformation. Les paramètres sont identifiés à partir des résultats d’expériences de compression dynamique (lanceur `a gaz, générateur de pression magnétique). La validité des modèles est testée en comparant les profils de vitesse calcul´es à l’aide d’un code dynamique explicite et les profils de vitesse mesurés lors des expériences. Ces modèles sont ensuite utilisés pour analyser les résultats obtenus lors d’expériences d’irradiation par faisceau d’électrons et de choc laser. Nous démontrons ainsi que les mousses polymères étudiées ont une forte capacité d’atténuation et que les modèles proposés sont valides à grande vitesse de déformation. / Polymeric foams are widely used in many industrial applications as thermal insulators, structural materials or shock mitigators. Indeed, they are light weight materials with an excellent weight /stiffness ratio and low production costs. One of the applications which interests the CEA is the protection of structures against mechanical loadings generated by laser irradiation or high velocity impact of small debris.The main objective of this PhD thesis is to investigate the mitigation capability of an expanded polyurethane foam and an epoxy syntactic foam against extremely fast (> 106 s−1) and intense(> 10 GPa) dynamic loadings. Cyclic quasi-static tests and dynamic experiments have been performed to investigate the behavior of these two foams for strain rates ranging from 10−3 to 106 s−1. Analysis of the experimental results shows that these polymeric foams have an elastic behavior phase followed by a compaction phase with significant permanent sets. Compaction thresholds are about 9 MPa for the polyurethane foam and 30 MPa for the epoxy foam under quasi-static loadings and around 21 MPa for the polyurethane foam and 72 MPa for the epoxy foam for strain rates above 104 s−1.Two porous compaction models are developed to represent the macroscopic behavior of these foams for such strain rates. The parameters are identified from the results of dynamic compression experiments (gas gun, low inductance generator). The validity of the models is tested by comparing calculated velocity profiles with an explicit hydrocode and velocity profiles measured during the experiments. These models are then used to analyze the results obtained with electron beam irradiation and laser-driven shock experiments. We demonstrate that the studied polymeric foam shave high mitigation capabilities and that the models are valid for high strain rates.

Development of foam cutting machines for rapid prototyping and manufacturing purposes began shortly after the first additive manufacturing machines became commercialised in the late 1980s. Increased computer power, the development and adoption of CAD/CAM software and rising demand for customisation has caused the rapid prototyping industry to grow swiftly in recent decades. While conventional rapid prototyping technologies are continuing to improve in speed and accuracy the ability to produce large (> 1m³) prototypes, moulds or parts it is still expensive, time consuming and often impossible. Foam cutting rapid prototyping and manufacturing machines are ideally suited to fulfil this niche because of their high speed, large working volumes and inexpensive working materials. Few foam cutting rapid prototyping machines have been commercialised to-date leaving significant opportunities for research and development in this area. Thermal plastic foam cutting is the material removal process most commonly used in foam cutting rapid prototyping to shape or sculpt the plastic foam into desired shapes and sizes. The process is achieved by introducing a heat source (generally a wire or ribbon) which alters the physical properties of the plastic foam and allows low cutting forces to be achieved. In thermal plastic foam cutting the heat source is generated via Joule (electrical) heating. This study investigates the plastic foam cutting process using experimental cutting trials and finite element analysis. The first part of this thesis presents an introduction to conventional foam cutting machines and rapid prototyping machines. It is suggested that a market opportunity lies out of reach of both of these groups of machines. By combining attributes from each, foam cutting rapid prototyping machines can be developed to fill the gap. The second part of this thesis introduces the state-of-the-art in foam cutting rapid prototyping and investigates previous research into plastic foam cutting mechanics. The third part of this thesis describes cutting trials used to determine important factors which influence plastic foam cutting. Collectively over 800 individual cutting tests were made. The cutting trials included two main material sets, expanded polystyrene and extruded polystyrene, three different wire diameters, two hot-ribbon configurations and a wide range of feed rates and power inputs. For each cut the cutting force, wire temperature and kerf width was measured as well as observations of the surface texture. The data was then analysed and empirical relationships were identified. An excel spreadsheet is established which allows the calculation of important outcomes, such as kerf width, based on chosen inputs. Quantitative measurements of the surface roughness and form, of cuts made with hot-tools, will not be addressed in this thesis. This body of work is currently under investigation by a colleague within the FAST group. The fourth part of this thesis describes the formation of a nonlinear transient two-dimensional heat transfer finite element model, which is developed for plastic foam cutting simulations. The conclusion is that the cutting trials contributed to a better understanding of plastic foam cutting mechanics. A new parameter was identified called the mass specific effective heat input, which is a function of the foam material and the cutting tool, it allows the prediction of cutting conditions with given cutting parameters and hence provides the necessary relationships needed for adaptive automated foam sculpting. Simulation results were validated by comparison with experimental data and provide a strong base for further developments including optimisation processes with adaptive control for kerf width (cut error) minimization. This study has added considerably to the pool of knowledge for foam cutting with a hot-tool. In general, much of the work reported herein has not been previously published. This work provides the most advanced study of foam sculpting work available to date.

Polymer nanocomposites are a going part of Materials Science and Engineering. These new composite materials exhibit dimensional and thermal stability of inorganic materials and toughness and dielectric properties of polymers. Development of nanocomposites become an important approach to create high-performance composite materials. In this study silica, fly ash, silica nanotubes and carbon black particles have been added to modify polyurethane foam and thermoplastic polyurethanes. It has been found that the addition of silica can diminish the size of foam bubbles, resulting in an increased stiffness of the material, increase of the compressive strength, and greater resistance to deformation. However, the uniformity of bubbles is reduced, resulting in increased friction of the material. Fly ash added to the foam can make bubbles smaller and improve uniformity of cells. Therefore, the material stiffness and compressive strength, resistance to deformation, and has little impact on the dynamic friction of the material. Adding nanotubes make bubble size unequal, and the arrangement of the bubble uneven, resulting in decreased strength of the material, while the friction increases. After the addition of carbon black to the polyurethane foam, due to the special surface structure of the carbon black, the foam generates more bubbles during the foaming process changing the foam structure. Therefore, the material becomes soft, we obtain a flexible polyurethane foam. The results of mechanical properties determination of the thermoplastic polyurethane that adding particles may increase the stiffness and wear resistance of the thermoplastic polyurethane, while the tensile properties of the material are reduced. This phenomenon may be due to agglomeration of particles during the mixing process. Possibly the particles cannot be uniformly dispersed in the thermoplastic polyurethane.

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ITC/USA 2010 Conference Proceedings / The Forty-Sixth Annual International Telemetering Conference and Technical Exhibition / October 25-28, 2010 / Town and Country Resort & Convention Center, San Diego, California / This research article reports a design of a wide band multilayer microstrip patch antenna (MSPA). Positions of a coaxial probe feed to main patch of the multilayer MSPA, widths and lengths of main and parasitic patches, and height of a Rohacell foam layer in the multilayer MSPA were optimized to achieve desired performance in L-band. The work also reports a design of a two-by-two array of multilayer MSPA. We present results on antenna radiation patterns and return loss obtained with full wave finite element simulations with Ansoft HFSS software and measurements with a vector network analyzer.

The interfacial properties of a surfactant in a CO₂-aqueous system at a temperature above 100 °C, and how they influence foams are essentially unknown. A cationic surfactant, C₁₂₋₁₄N(EO)₂ in the protonated state below pH 5.5, was demonstrated to be soluble in an aqueous phase with up to 22% total dissolved salt (TDS) at 120 °C. Moreover, the strong solvation in brine (high cloud point) and simultaneous affinity for CO₂ led to significant adsorption of the surfactant at the CO₂-water interface. Given that the surfactant favored the brine phase over the CO₂ phase, the preferred curvature was a CO₂-in-water (C/W) macroemulsion (foam). The surfactant stabilized foam in the presence of crushed calcium carbonate at ~ pH 4 upon suppressing the dissolution of calcium carbonate upon addition of Ca²⁺ and Mg²⁺ according to the common ion effect. Cationic alkyltrimethylammonium surfactants with an alkyl tail of average carbon number less than 15 were soluble in 22% TDS brine up to 120 oC. The head group was properly balanced with a C₁₂₋₁₄ hydrocarbon tail for a sufficiently dense surfactant layer at the CO₂-water interface to reduce the interfacial tension. For C₁₂₋₁₄N(CH₃)₃Cl the solubility in brine and the surfactant adsorption were sufficient to stabilize C/W foam at 120 °C in both a crushed calcium carbonate packed bed (76 Darcy) and a capillary tube at the downstream of the bed. The stability of the foam at high temperature may be attributed to the high surfactant adsorption at the interface. The use of nonionic surfactants as a foam stabilizer is usually limited by their poor aqueous solubility at elevated temperatures, particularly at high salinity. A nonionic surfactant C₁₂₋₁₄(EO)₂₂ with high degree of ethoxylation gave higher salt tolerance at elevated temperature. The surfactant stabilize C/W foam at 80 °C in the presence of 90 g/L NaCl brine in a 30 Darcy sand pack, which has not yet been reported by a nonionic surfactant. Both the formation of strong foam in the porous media and the low of oil-brine partition coefficient suggest C₁₂₋₁₄(EO)₂₂ is a potential candidate for a CO₂ EOR field trial. / text