Aluminium Alloy Foam Modelling and Prediction of Elastic Properties Using X-ray Microcomputed Tomography

Abstract

X-ray microcomputed tomography has been gaining relevance in the field of cellular materials to characterize materials and analyse their microstructure. So, here, it was used together with finite element modelling to develop numerical models to estimate the effective properties (Young’s modulus) of aluminium alloy foams and evaluate the effects of processing on the results. A manual global thresholding technique using the mass as a quality indicator was used. The models were reconstructed (Marching Cubes 33), then simplified and analysed in terms of mass and shape maintenance (Hausdorff distance algorithm) and face quality. Two simplification procedures were evaluated, with and without small structural imperfections, to evaluate the impact of the procedures on the results. Results demonstrate that the developed procedures are good at minimizing changes in mass and shape of the geometries while providing good face quality, i.e., face aspect ratio. The models are also shown to be able to predict the effective properties of metallic foams in accordance with the findings of other researchers. In addition, the process of obtaining the models and the presence of small structural imperfections were shown to have a great impact on the results.