A methodology for ligament isolation and specimen preparation for tensile testing of single ligaments from the unit cell of open-cell carbon foams has been successfully developed and implemented. Results are presented for ligaments of three different carbon foam designations. Two of them are reticulated vitreous carbon (RVC) foams of 20 and 45 pores-per- inch (ppi) coated with SiC by chemical vapor deposition (CVD) and the other is a RVC 20 ppi foam without coating. Scanning electron microscopy and digital imaging analysis is used to analyze the fracture surfaces posts tests. The ultimate strength of each ligament evaluated. Weibull statistics is used to describe the strength distribution of ligaments. While the distribution of strengths of the carbon foam ligaments (RVC) could be described with a one-population distribution, it is found that a two-population Weibull distribution is necessary to describe the distribution of strength of the SiC coated ligaments.

No description available.

No description available.

The focus of this research is characterizing a new material system composed of carbon and graphite foams, which has potential in a wide variety of applications encompassing aerospace, military, offshore, power production and other commercial industries. The benefits of this new material include low cost, light weight, fire-resistance, good energy absorption, and thermal insulation or conduction as desired. The objective of this research is to explore the bulk material properties and failure modes of the carbon foam through experimental and computational analysis in order to provide a better understanding and assessment of the material for successful design in future applications. Experiments are conducted according to ASTM standards to determine the mechanical properties and failure modes of the carbon foam. Sandwich beams composed of open cell carbon foam cores and carbon-epoxy laminate face sheets are tested in the flexure condition using a four point setup. The primary failure mode is shear cracks developing in the carbon foam core at a critical axial strain value of 2,262 με. In addition to flexure, the carbon foam is loaded under tensile and shear loads to determine the respective material moduli. Computational analysis is undertaken to further investigate the carbon foam's failure modes and material characteristics in the sandwich beam configuration. Initial estimates are found using classical laminated plate theory and a linear finite element model. Poor results were obtained due to violation of assumptions used in both cases. Thus, an additional computational analysis incorporating three dimensional strain-displacement relationships into the finite element analysis is used. Also, a failure behavior pattern for the carbon foam core is included to simulate the unique failure progression of the carbon foam on a microstructure level. Results indicate that displacements, strains and stresses from the flexure experiments are closely predicted by this two parameter progressive damage model. The final computational model consisted of a bond line (interface) study to determine the source of the damage initiation, and it is concluded that damage initiates in the carbon foam, not at the bond line.

As technological advances occur, many conventional materials are incapable of providing the unique multi-functional characteristics demanded thus driving an accelerated focus to create new material systems such as carbon and graphite foams. The improvement of their mechanical stiffness and strength, and tailoring of thermal and electrical conductivities are two areas of multi-functionality with active interest and investment by researchers. The present research focuses on developing models to facilitate and assess multi-functional carbon foams in an effort to expand knowledge. The foundation of the models relies on a unique approach to finite element meshing which captures the morphology of carbon foams. The developed models also include ligament anisotropy and coatings to provide comprehensive information to guide processing researchers in their pursuit of tailorable performance. Several illustrations are undertaken at multiple scales to explore the response of multi-functional carbon foams under coupled field environments providing valuable insight for design engineers in emerging technologies. The illustrations highlight the importance of individual moduli in the anisotropic stiffness matrix as well as the impact of common processing defects when tailoring the bulk stiffness. Furthermore, complete coating coverage and quality interface conditions are critical when utilizing copper to improve thermal and electrical conductivity of carbon foams.

As technological advances occur, many conventional materials are incapable of providing the unique multi-functional characteristics demanded thus driving an accelerated focus to create new material systems such as carbon and graphite foams. The improvement of their mechanical stiffness and strength, and tailoring of thermal and electrical conductivities are two areas of multi-functionality with active interest and investment by researchers. The present research focuses on developing models to facilitate and assess multi-functional carbon foams in an effort to expand knowledge. The foundation of the models relies on a unique approach to finite element meshing which captures the morphology of carbon foams. The developed models also include ligament anisotropy and coatings to provide comprehensive information to guide processing researchers in their pursuit of tailorable performance. Several illustrations are undertaken at multiple scales to explore the response of multi-functional carbon foams under coupled field environments providing valuable insight for design engineers in emerging technologies. The illustrations highlight the importance of individual moduli in the anisotropic stiffness matrix as well as the impact of common processing defects when tailoring the bulk stiffness. Furthermore, complete coating coverage and quality interface conditions are critical when utilizing copper to improve thermal and electrical conductivity of carbon foams.

Carbon foams exhibit numerous unique properties which are attractive for light weight applications such as aircraft and spacecraft as a tailorable material. Carbon foams, when exposed to air, oxidize at temperatures as low as 500-600 degrees Celsius. The research objectives of this study are to assess the degree of oxidation of carbon foam by experimental and computational methods and evaluate the degradation in stiffness of the bulk foam as a function of oxygen concentration profile, time and temperature. In parallel to simulation, oxidation tests are conducted to observe changes in morphology and to calculate the apparent activation energy. Degradation patterns in the carbon foam microstructure are categorized through optical microscopy (OM) images post oxidation. The influence of microstructure and temperature on the oxygen concentration profile is investigated in parametric models with varying porosity. The degradation in bulk foam stiffness is found to be strongly dependent on the temperature and non-uniform oxygen concentration profile. The overall results enhance the design of experiments for high temperature and oxidative environments, illustrating the relationship between foam microstructure and oxygen concentration in porous media.

The focus of this research is characterizing a new material system composed of carbon and graphite foams, which has potential in a wide variety of applications encompassing aerospace, military, offshore, power production and other commercial industries. The benefits of this new material include low cost, light weight, fire-resistance, good energy absorption, and thermal insulation or conduction as desired. The objective of this research is to explore the bulk material properties and failure modes of the carbon foam through experimental and computational analysis in order to provide a better understanding and assessment of the material for successful design in future applications. Experiments are conducted according to ASTM standards to determine the mechanical properties and failure modes of the carbon foam. Sandwich beams composed of open cell carbon foam cores and carbon-epoxy laminate face sheets are tested in the flexure condition using a four point setup. The primary failure mode is shear cracks developing in the carbon foam core at a critical axial strain value of 2,262 με. In addition to flexure, the carbon foam is loaded under tensile and shear loads to determine the respective material moduli. Computational analysis is undertaken to further investigate the carbon foam's failure modes and material characteristics in the sandwich beam configuration. Initial estimates are found using classical laminated plate theory and a linear finite element model. Poor results were obtained due to violation of assumptions used in both cases. Thus, an additional computational analysis incorporating three dimensional strain-displacement relationships into the finite element analysis is used. Also, a failure behavior pattern for the carbon foam core is included to simulate the unique failure progression of the carbon foam on a microstructure level. Results indicate that displacements, strains and stresses from the flexure experiments are closely predicted by this two parameter progressive damage model. The final computational model consisted of a bond line (interface) study to determine the source of the damage initiation, and it is concluded that damage initiates in the carbon foam, not at the bond line.

No description available.

No description available.