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Low-density cellular solids have demonstrated superior mechanical properties as well as multifunctional characteristics, which may provide a basis for the development of novel structured materials. In particular, cellular solids offer great design flexibility, owing to their topology, which can provide desired functionalities via targeted geometric design and proper selection of the constituent material. While stochastic configurations such as metallic foams have proven to be effective for both thermal insulation and mechanical-energy absorption, the topology of deterministic architectures is not constrained by physical processes. This allows for a variety of configurations to be tailored to simultaneously fulfill disparate tasks. An additional aspect of deterministic cellular structures is the possibility of assembling materials or structures by the spatial repetition of a unit cell. The resulting periodicity of such systems simplifies the characterization of physical properties, which can be established by analyzing the unit cell only, and will provide new opportunities in the fields of structural dynamics, where periodicity-induced impedance leads to the control of both constructive and destructive interference on propagating waves. The objective of this work is to investigate the application of the chiral cellular topology for the design of novel macrostructural, mesostructural and microstructural configurations. A truss-core airfoil, and a truss-core beam are employed as a basis to demonstrate both large-displacement capabilities within the elastic regime of the constituent material, as well as operational deflection shapes with localized dynamic deformations. Large deformation capabilities and unique operational deflection shapes are to be attributed to the unusual deformation mechanism of the chiral lattice. Mesostructural and microstructural configurations, on the other hand, are characterized by an unique mechanical behavior, complex geometry, as well as geometric design flexibility to control both static and dynamic phenomena. The propagation of elastic waves, moreover, is characterized by significant band-gap density as well as strong energy focusing dependent on frequency and wavenumber. These features suggest the chiral topology as a basis for the development of acoustic meta-materials.

Shape memory polymer (SMP) materials have the ability to remain in a deformed state and then recover their initial/cast shape. This property has significant potential in many different fields, including aerospace and bio-medical, in which a shape change is desirable and actuation may not be required. SMP materials have been made into nano-reinforced composites and also foamed to improve desired properties for specific applications. SMP foams offer two clear advantages over non-foam SMP materials in applications for the biomedical and aerospace fields. The key advantages are lower density and significant compressibility. The significance of this is that components made out of SMP foam are lighter than traditional SMP materials, more compressible and exhibit minimal transverse change during deformation and shape recovery. This increases the performance and efficiency of devices using SMP foam material. The need for a set of design criteria, models, and limits for the use of shape memory polymer foams was proposed. The effect of temperature and strain on the mechanical behavior, compression, tensile, cyclic compression, constrained recovery and free strain recovery of the material was used to determine the operational limits of the material. Next, the damage mechanism and viscoelastic effects in compressive cycling were determined through further mechanical testing and with the incorporation of three dimensional structure mapping via micro-CT scanning. The influence of microstructure was determined by testing the basic thermomechanical, viscoelastic and shape recovery behavior of foams with relative densities of 20, 30 and 40 percent. A similar suite of tests was then performed on the base epoxy material to generate the material properties necessary to fit constitutive equations to enable computational modeling. This data was then combined with three dimensional microstructures generated from micro-CT scans to develop material models for shape memory foams. These models were then validated by comparing model results to the experimental results under similar conditions.

Thesis (Ph. D.)--Ohio State University, 2007. / Title from first page of PDF file. Includes bibliographical references (p. 152-167).

Low-density cellular materials, metallic bodies with gaseous voids, are a unique class of materials that are characterized by their high strength, low mass, good energy absorption characteristics, and good thermal and acoustic insulation properties. In an effort to take advantage of this entire suite of positive mechanical traits, designers are tailoring the cellular mesostructure for multiple design objectives. Unfortunately, existing cellular material manufacturing technologies limit the design space as they are limited to certain part mesostructure, material type, and macrostructure. The opportunity that exists to improve the design of existing products, and the ability to reap the benefits of cellular materials in new applications is the driving force behind this research. As such, the primary research goal of this work is to design, embody, and analyze a manufacturing process that provides a designer the ability to specify the material type, material composition, void morphology, and mesostructure topology for any conceivable part geometry. The accomplishment of this goal is achieved in three phases of research: Design Following a systematic design process and a rigorous selection exercise, a layer-based additive manufacturing process is designed that is capable of meeting the unique requirements of fabricating cellular material geometry. Specifically, metal parts of designed mesostructure are fabricated via three-dimensional printing of metal oxide ceramic powder followed by post-processing in a reducing atmosphere. Embodiment The primary research hypothesis is verified through the use of the designed manufacturing process chain to successfully realize metal parts of designed mesostructure. Modeling & Evaluation The designed manufacturing process is modeled in this final research phase so as to increase understanding of experimental results and to establish a foundation for future analytical modeling research. In addition to an analysis of the physics of primitive creation and an investigation of failure modes during the layered fabrication of thin trusses, build time and cost models are presented in order to verify claims of the process s economic benefits. The main contribution of this research is the embodiment of a novel manner for realizing metal parts of designed mesostructure.

Thesis (MScEng (Mathematical Sciences. Applied Mathematics))--University of Stellenbosch, 2006. / This work entails the improvement of an existing three dimensional pore-scale model. Stagnant zones are included, the closure of the volume averaged pressure gradient is improved and an improved calculation of pore-scale averages, using the RUC, is done for the model to be a more realistic representative of the REV and thus of the foamlike material. Both the Darcy and the Forchheimer regimes are modelled and a general momentum transport equation is derived by means of an asymptotic matching technique. The RUC model is also extended to cover non-Newtonian flow. Since metallic foams are generally of porosities greater than 90%, emphasis is put on the accurate prediction of permeability for these porosities. In order to improve permeability predictions for these high porosity cases an adaptation to the RUC model was considered, whereby rectangular prisms were replaced by cylinders. Although this adaptation appears to give more accurate permeabilities at very high porosities, its implementation in a generalised model seems impractical. The prediction of the characteristic RUC side length is discussed and results of both the cylindrical strand model and the square strand model are compared to experimental work.

Les mousses minérales sont des matériaux alvéolaires utilisables en isolation thermique répartie. L’objectif de ces travaux de recherche est de développer, à partir d’une suspension très concentrée de liants hydrauliques, des mousses légères présentant de bonnes performances mécaniques et thermiques. L’introduction de tensioactif est nécessaire à la formation des mousses minérales. Six molécules tensioactives sont sélectionnées dans cette étude. Leurs capacités à réduire la tension de surface et à stabiliser une mousse aqueuse sont évaluées. Deux groupes de tensioactifs sont distingués sur la base de différents critères : tension de surface, CMC, stabilité de la mousse. Les suspensions minérales concentrées sont des fluides à seuil. L’étude du comportement de bulles formées dans de tels fluides est réalisée à l’aide d’un fluide à seuil modèle transparent, le Carbopol®, et d’un système d’injection à pression contrôlée. Le seuil de mise en écoulement affecte les conditions de formation, de croissance, de stabilité et d’évolution de la forme des bulles en modifiant la distribution des pressions au voisinage de la bulle. L’étude permet de proposer une équation de Laplace modifiée prenant en compte l’influence de la sphéricité et du seuil de cisaillement. L’introduction du tensioactif affecte les conditions de contact entre bulles et permet de contrôler le risque de coalescence. En cas de rupture de membrane, la présence du seuil de cisaillement conduit à une géométrie particulière des bulles coalescées. Les liants minéraux choisis sont un sulfate de calcium anhydre particulièrement réactif, un ciment Portland et un ciment prompt. La formulation des suspensions découle d’un critère de fluidité. La pâte fraîche est caractérisée par un seuil de cisaillement faible. Sa masse volumique apparente dépend de la nature et du dosage en tensioactif. Les mousses minérales sont générées à partir d’une composition identique. Deux méthodes de moussage traditionnelles : malaxage simple et mousse préformée et une méthode alternative : la méthode dissociée, sont exploitées. Les meilleures performances thermomécaniques des mousses durcies sont obtenues avec la méthode dissociée, méthode spécifique au laboratoire et peu énergivore. Un groupe de tensioactifs permet d’obtenir des mousses peu denses satisfaisant simultanément aux critères de performances thermomécaniques fixés. Pour ces tensioactifs, un dosage caractéristique est identifié permettant une optimisation des performances mécaniques. Des visualisations réalisées au MEB révèlent des modifications sensibles de la structure cristalline fonction du tensioactif employé et de son dosage. Les structures les plus fines et homogènes sont les plus résistantes. Les performances des mousses et leur structure porale sont donc liées. Pour analyser quantitativement la structure porale, les distributions alvéolaires surfaciques sont construites puis comparées aux distributions alvéolaires volumiques obtenues par tomographie. Une méthode analytique de passage 2D/3D est créée en s’appuyant sur les principes de la stéréologie. Un coefficient de correction est proposé pour tenir compte de la représentativité de la surface étudiée. La maîtrise de toutes les étapes de fabrication des mousses minérales ainsi que la compréhension des phénomènes physiques intervenant tout au long de la production d’une mousse (de la suspension minérale jusqu’à la mousse durcie) permettent d’obtenir des produits satisfaisant les objectifs fixés : légèreté, isolation et caractère porteur. / Mineral foams are cellular materials usable as thermal insulation solution. The purpose of these PhD researches is to develop lightweight foams with good thermal and mechanical performances realized from highly concentrated mineral suspension. Surfactant addition is required for foaming. Six surfactants molecules are selected. Their abilities to reduce surface tension and to stabilize aqueous foam are evaluated. Two surfactants groups are detected based on different criteria: surface tension, CMC and aqueous foam stability. Concentrated mineral suspensions are yield stress fluids. The study of bubbles behavior in such fluids is performed with a transparent yield stress fluid, Carbopol® and an injection device with controlled pressure. Yield stress impacts bubbles creation, growth, stability and shape by changing local pressure distribution in the fluid nearby bubble. The study proposes a revised Laplace law depending on yield stress and bubble sphericity. Contact conditions between bubbles are influenced by surfactant addition allowing to control coalescence phenomena. In case of inter-bubbles membrane breakage, presence of yield stress leads to particular geometry of the coalesced bubbles. Mineral binders selected are a highly reactive anhydrous calcium sulfate, ordinary Portland and prompt cements. Mineral suspension formulations arise from expected fluidity criterion. Fresh paste is characterized by a low yield stress. Its bulk density depends on surfactant nature and content. Mineral foams are created with same composition. Two traditional foaming methods: mix-foaming and pre-foaming and an alternative one, the dissociated method are employed. Best thermo-mechanical performances are achieved with the dissociated method, a specific method of the laboratory. A surfactant group leads to lightweight foams which simultaneously fulfills both thermal and mechanical targeted objectives. For these surfactants a characteristic content is found leading to optimized mechanical performances. Visualizations performed with SEM reveal sensitive crystalline structure modifications depending on surfactant nature and content. Thinner and more homogeneous structures are associated with the best mechanical performances which demonstrates the existing link between the porous structure and mineral foams mechanical performances. To quantitatively evaluate porous structure, surface bubble-size distributions are built and then compared to volume bubble-size distributions obtained by tomography analysis. An analytic method linking 2D and 3D distributions is created based on stereology principles. A correction coefficient is proposed to take into account the analyzed representative surface. By controlling all production steps and associated physical phenomena during mineral foams production (from mineral suspension to solid foams), products satisfying all targeted objectives are realized: lightness, insulation and load-bearing ability.

Excessive fluid-borne noise in hydraulic systems is a problem the fluid power industry has long struggled to address. Traditional noise control devices such as Helmholtz resonators, tuning coils, and Herschel-Quincke tubes are generally too large for fluid power systems unless the speed of sound in the device can be reduced. A compliant lining can achieve this effect, but compliance (and lossy compliance) has had little attention in noise control in general, and in fluid power in particular. One means to achieve compliance in these devices, especially at elevated pressures, is through a liner made of syntactic foam, which in this case is a urethane host matrix with embedded hollow, polymer microspheres. The material properties at elevated pressure are unknown by the liner manufacturer, but are known to be pressure- and temperature-dependent. Therefore, the effect of hydrostatic pressures from 2.1-21 MPa and temperatures from 20-45 C on the liner properties, thus the device performance, are studied. For a Helmholtz resonator, a theoretical model is fit to experimentally-measured transmission loss of the device using a least-squares routine, which solves the inverse problem for the complex bulk modulus of the liner. These material properties are used to compare a predictive model of a tuning coil to experimental data, and in a parameter study of a Herschel-Quincke tube. The compliance of the liner is found to lower the effective sound speed by an order of magnitude and decrease the volume of the cavity of a Helmholtz resonator by up to two orders of magnitude. This work is expected to result is more compact noise control devices for fluid power systems.

Natural disasters are affecting a significant number of people around the world. Sheltering is the first step in post-disaster activities towards the normalization of the affected people's lives. Temporary housing is being used in these cases until the construction of permanent houses are done. Disposal of temporary housing after use is leading to a significant environmental impact because most of them are filled with thermally insulative polymer foams that do not degrade in a short period. To reduce these problems this work proposes to use foams made with compostable thermoplastic polylactic acid (PLA) and degradable kenaf core as filler materials; these foams are made using CO2 as blowing agent for insulation purposes. Foams with PLA and 5%, 10% and 15% kenaf core were tested. Different properties and their relations were examined using differential scanning calorimetry (DSC), thermal conductivity, mechanical properties, scanning electron microscopy (SEM), x-ray μ-computed tomography (μ-CT) and building energy simulations were done using Energy Plus by NREL. The results show that mechanical properties are reduced with the introduction of kenaf core reinforcement while thermal conductivity display a noticeable improvement.