Tensile fatigue of conventional and negative Poisson’s ratio open cell PU foams

In this paper, we present a comparative analysis between the cyclic loading tensile behaviour of conventional and auxetic thermoplastic PU foams. While the two types of foam share the same base material (open cell PU–PE), one batch is transformed into an auxetic one (i.e., negative Poisson’s ratio) using a special manufacturing process involving moulding and exposure to particular temperature profiles to stabilise the transformation of the microstructure. The effect of the stiffness degradation and accumulation of energy dissipation versus the number of cycles are discussed for different loading levels r. The results show that the fatigue behaviour until failure, subjected to cyclic loading depends on the loading levels and occur in three stages. The results obtained shows also that the auxetic foam have enhanced characteristics under static loading and tensile fatigue compared to the conventional parent phase form.     

Piezoresistive and compression resistance relaxation behavior of water blown carbon nanotube/polyurethane composite foam

The in-situ bulk polycondensation process in combination with a ball milling dispersion process was used to prepare the water blown multiwall carbon nanotubes (CNT)/polyurethane (PU) composite foam. The mechanical properties, piezoresistive properties, strain sensitivity, stress and resistance relaxation behaviors of the composite foams were investigated. The results show that the CNT/PU composite foam has a better compression strength than the unfilled polyurethane foams and a negative pressure coefficient behavior under uniaxial compression. The resistance response of CNT/PU nanocomposites foam under cyclic compressive loading was quite stable. The nanocomposite foam containing a weight fraction of carbon nanotubes close to the percolation threshold presents the largest strain sensitivity for the resistance. The characteristic of resistance relaxation of CNT/PU composite foam is different from the stress relaxation due to the different relaxation mechanism. During compressive stress relaxation, the CNT/PU foam composites have excellent resistance recoverability while poor stress recoverability.     

Physical and thermal effects on the shape memory behaviour of auxetic open cell foams

This study examines the processing envelope related to auxetic open cell foams and their shape memory properties, with the analysis of four different phases of multi-component foams (conventional, 1st auxetic, returned and 2nd auxetic). The analysis of the shape memory and its correlation with negative Poisson’s ratio behaviour are a novelty in the field of auxetic materials. This study describes the differences between the multi-component foams used as precursors for each phase, exploring their mechanical and thermal characteristics at each stage of the conversion. The results show the important differences related to the mechanical behaviour of the foams, due essentially to the axial compression adopted during the manufacturing process.     

SiC-particulate aluminum composite foams produced from powder compacts: foaming and compression behavior

The foaming behavior of SiC-particulate (SiC_p) aluminum composite powder compacts containing titanium hydride blowing agent was investigated by heating to 750°C in a pre-heated furnace. Aluminum powder compacts were also prepared and foamed using similar compaction and foaming parameters in order to determine the effect of SiC_p-addition on the foaming and compression behavior. The SiC_p-addition (10 wt%) was found to increase the linear expansion of the Al powder compacts presumably by increasing the surface as well as the bulk viscosities. The compression tests conducted on Al and 10 and 20% SiC_p foams further showed a more brittle compression behavior of SiC_p/Al foams as compared with Al foams. The collapse stresses of Al and 10% SiC_p/Al foams were also predicted using the equations developed for the open and closed cell foams. Predictions have shown that Al foam samples behaved similar to open cell foams, while 10% SiC_p/Al foam collapse stress values were found between those of open and closed cell foams, biasing towards those of the open cell foams.     

Reticulated macroporous ceramic foam supported TiO2 for photocatalytic applications

Ceramic macroporous reticular alumina foams with a pore size of 15, 20 and 25 pores per inch (ppi) were prepared by the Schwartzwalder method and sintered at 1200 °C to preserve a high porosity. TiO₂ thick films were supported on the foam surface by a wash coating process, using Degussa P25 as a TiO₂ nanopowder source. After annealing at 600 °C, films with an adequate adhesion and with a thickness of 5–10 μm were obtained. An increasing pore size of the supported foams improves the specific photocatalytic activity of the TiO₂ coated scaffolds, the flow of solution through the highly active porous foam structure and the better access of light to the active TiO₂ surface.     

Development of rigid bio-based polyurethane foam reinforced with nanoclay

Integration of organic nanoclay into bio-based polyurethane (PU) foam is a promising alternative to enhance the foam’s properties via green technology. In this paper, modified diaminopropane montmorillonite (DAP-MMT) nanoclay was introduced into palm oil-based PU foam at different weight loadings, namely, 0, 2, 4, 6, 8, and 10 wt.%, in order to investigate the effects on the mechanical and thermal properties of the foam. Several tests and characterizations were carried out to study the surface morphology, density, compressive strength and thermal stability of the foam. It was found that foam exhibited an exfoliated or intercalated microstructure based on the DAP-MMT contents. The X-ray diffraction analysis showed that below 4 wt.%, the foams displayed exfoliated structures while beyond the value, the foams exhibited the intercalated morphologies. Closed cells with different cell sizes were observed when the DAP-MMT contents were varied. Meanwhile, thermal stability and compressive strength of foams increased with increasing DAP-MMT contents up to 4 wt.%, as shown by thermogravimetry analysis and compression test, respectively.     

Tailoring properties of reticulated vitreous carbon foams with tunable density

Reticulated vitreous carbon (RVC) foams were manufactured by multiple replications of a polyurethane foam template structure using ethanolic solutions of phenolic resin. The aims were to create an algorithm of fine tuning the precursor foam density and ensure an open-cell reticulated porous structure in a wide density range. The precursor foams were pyrolyzed in inert atmospheres at 700°C, 1100°C and 2000°C, and RVC foams with fully open cells and tunable bulk densities within 0.09–0.42 g/cm³ were synthesized. The foams were characterized in terms of porous structure, carbon lattice parameters, mechanical properties, thermal conductivity, electric conductivity, and corrosive resistance. The reported manufacturing approach is suitable for designing the foam microstructure, including the strut design with a graded microstructure.     

Enhancing mechanical and fracture properties of sandwich composites using nanoparticle reinforcement

Polyurethane (PU) foam is reinforced with SiC nanoparticles to develop core materials for sandwich composites. Isocyanate component (Part A) of PU foam was dispersed with SiC nanoparticles, and then mixed with polyol (Part B) to manufacture nanophased core materials. Nanoparticle reinforcement varied from 0.1 to 2.0 wt% of the total polymer. Both pristine and silane functionalized SiC nanoparticles were used in the investigation. Nanophased foams were tested in compression and flexure to determine the mechanical properties. Fracture toughnesses K _IC and G _IC were determined using the SENB test. Sandwich panels were fabricated and tested for face-core debond fracture toughness using the tilted sandwich debond test. The study has revealed that reinforcement of the foam by pristine nanoparticles substantially enhances mechanical properties but degrades fracture toughness. This loss in fracture toughness, however, may be recovered with the use of functionalized nanoparticles. Small concentrations (0.1–0.2 wt%) of functionalized nanoparticles provided large improvement in debond fracture toughness of sandwich specimens.     

Effects of winding angle on the behaviour of glass/epoxy pipes under multiaxial cyclic loading

The effects of winding angle on the behaviour of glass/epoxy composite tubes under multiaxial cyclic loading were investigated. The performance of such composite tubes was studied using an indigenous automated test procedure that is compatible with the internal qualification requirements of the composite pipe manufacturers. Glass fibre reinforced epoxy (GRE) composite pipes with three winding angles, namely, [± 45°]₄, [± 55°]₄, and [± 63°]₄, were tested. A novel automated test rig was fabricated to accommodate five stress ratios, ranging from pure axial to pure hoop loadings. The cyclic pressure test was conducted until droplets of water were seen on the outer surface of the pipe. Failure envelopes were then constructed based on the first ply failure (FPF) points determined from the axial stress to hoop strain response at five stress ratios. Three functional failure modes, namely, tensile axial, weepage, and local leakage failures, were observed during the tests. The results indicate that each winding angle dominates a different optimum pressure loading condition, namely, [± 55°]₄ for pure hydrostatic loading, [± 45°]₄ for hoop to axial loading, and [± 63°]₄ for quad hoop to axial loading. The envelopes show a strong dependence on the stress ratio and winding angle.     

Influence of temperature and thickness on the off-axis behaviour of short glass fibre reinforced polyamide 6.6 – cyclic loading

This paper investigates the anisotropic properties of short glass fibre reinforced polyamide 6.6 (PA66-GF35) under tension–tension and tension–compression cyclic loading. Tensile fatigue tests were carried out on dog-bone specimens, machined out from injection-moulded plates 80 × 80 mm, of three different thicknesses t (1 and 3 mm) at three different nominal fibre orientation angles θ (0°, 30° and 90°). The tests were carried out at RT as well as at 130 °C.The Tsai–Hill failure criterion, modified to account for cyclic loading, is applied to the fatigue data for estimating the fatigue strength parameters of the material under investigation. Results are compared to the strength parameters obtained under quasi-static loading in a previous part of this work [De Monte M, Moosbrugger E, Quaresimin M. Influence of temperature and thickness on the off-axis behaviour of short glass fibre reinforced polyamide 6.6 – quasi-static loading. Composites: Part A, 2010;41(10):1368–79]. The experimental results highlight how specimen thickness remarkably affects mechanical properties: the thinner the specimen the higher will be the degree of anisotropy. Also temperature strongly reduces the fatigue strength under cyclic loading. The Tsai–Hill criterion allows for an adequate fitting of experimental data at the investigated temperatures and load ratios.     

Manufacture of biodegradable packaging foams from agar by freeze-drying

Cellular foams were made from the aqueous solution of agar by freeze-drying. A narrow range (5–20°C min-1) of freezing rate was required to avoid damage to the microstructure of the agar foams. The size of cells in the foam decreased with increasing freezing rate. Agar foams of more than 4 wt% agar content absorbed more energy than a polystyrene foam in compression tests. Foams with a higher agar content absorbed more energy. The behaviour of agar foams in compression tests could be explained by the modified beam theory for cellular foams. Agar foams were thermally stable up to 200°C, and were also stable in a humid environment. This revised version was published online in November 2006 with corrections to the Cover Date.     

Tensile strength degradation of ceramic fibres due to cyclic loading

Interfacial strength of Ti β 21S/SCS 6 composite was increased via ageing. Composite specimens with a_o/W ratios of 0.24 and 0.07 were prefatigued in three point bending at ambient and at 500 °C both in the air and vacuum. Bridging fibres were extracted from the pre-fatigued specimens and tested in tensile loading to monitor the strength degradation due repeated opening and closing of the fatigue crack. A tri-modal Weibull distribution was employed to express strength distribution of the SCS 6 fibres. Results have shown that cyclic loading of the composites lower the mean tensile strength of the fibres by 20%, compared to the unfatigued composite. A marked effect of initial unbridged defect size was observed, when the tensile strength data were divided into two sub-population using the fatigue crack length values. Compared to unfatigued composite, tensile strength reductions of 41 and 22% were measured from the prefatigued composites with a_o/W of 0.24 and 0.07, respectively.     

Effect of the oxygen content in solution on the static and cyclic deformation of titanium foams

It is well known that interstitials affect the mechanical properties of titanium and titanium alloys. Their effects on the fatigue properties of titanium foams have not, however, been documented in the literature. This paper presents the effect of the oxygen content on the static and dynamic compression properties of titanium foams. Increasing the oxygen content from 0.24 to 0.51 wt% O in solution significantly increases the yield strength and reduces the ductility of the foams. However, the fatigue limit is not significantly affected by the oxygen content and falls within the 92 MPa ± 12 MPa range for all specimens investigated in this study. During cyclic loading, deformation is initially coming from cumulative creep followed by the formation of microcracks. The coalescence of these microcracks is responsible for the rupture of the specimens. Fracture surfaces of the specimens having lower oxygen content show a more ductile aspect than the specimens having higher oxygen content.     

Soft-type polyurethane foams derived from molasses

Molasses (ML)-based soft-type polyurethane (PU) foams were successfully prepared by controlling evolved heat during chemical reaction. Two kinds of isocyanate, poly(phenylene methylene) polyisocyanate (MDI) and tolylene diisocyanate (TDI), and polypropylene glycol with a long molecular chain length were utilized to control the chemical reaction. The hydroxyl group in ML was used as the reaction site and soft-type PU foams were synthesized at isocyanate (NCO)/hydroxyl group (OH) ratios of 1.05. Mechanical properties of the above foams were controlled by changing the mixing ratio of MDI and TDI. Pore size and distribution were measured by scanning electron microscopy. With increasing thickness of cell wall, compression strength and modulus increased. Thermal properties of PU foams were investigated by differential scanning calorimetry, thermogravimetry, and thermal conductivity measurements. Two-step glass transition temperatures were observed at around ca. ?55 and 80 °C, regardless of kind of isocyanate. The low temperature side glass transition is attributed to the molecular motion of long oxyethylene chains and the high temperature side transition is caused by rigid components including saccharide components. Thermal decomposition of PU foams started from ca. 270 °C. Thermal conductivity of soft-type PU was observed in a range from 0.034 to 0.035 J s^?1 m^?1 K^?1.     

Performance improvements of aluminum foam with different solder compositions via liquid diffusion welding

Aluminum foam joints were fabricated via liquid diffusion welding with zinc-aluminum alloy solder aided with ultrasonic vibration at 520 °C. Zinc-aluminum alloys with different compositions (10 % aluminum, 20 % aluminum, 30 % aluminum) were used as solder material. The control group was fabricated under the same conditions but without ultrasonic assistance. The microstructure of aluminum foam joints was analyzed by optical microscopy, scanning electron microscopy, and energy dispersive spectroscopy. Among the different soldering alloys, those with the zinc-20aluminum solder had the widest diffusion area and the most continuous interface. The tensile strength of metallurgic alloy joined aluminum foams was tested. Zn20Al samples had the best performance among all samples, including the low-density substrate aluminum foam (0.3 g/cm³ and 0.4 g/cm³), but it still showed a lower performance than the high-density substrate aluminum foam (0.6 g/cm³). Therefore, ultrasonic vibration remarkably improved the tensile strength and impact toughness of joints. Samples with ultrasonic assistance had better tensile strength and impact toughness than high-density substrate aluminum.     

Fabrication methods for auxetic foams

Auxetic materials have a negative Poisson's ratio, that is, they expand laterally when stretched longitudinally. Negative Poisson's ratio is an unusual property that affects many of the mechanical properties of the material, such as indentation resistance, compression, shear stiffness, and certain aspects of the dynamic performance. The unusual mechanical properties of auxetic foams are attributed to the deformation characteristics of re-entrant microstructures. One way of obtaining negative Poisson's ratio is by using a re-entrant cell structure. Auxetic foam was fabricated from a conventional polymeric foam. The fabrication method for making both small and large auxetic foam specimens is described. This revised version was published online in November 2006 with corrections to the Cover Date.     

Stainless steel foams made through powder metallurgy route using NH4HCO3 as space holder

Stainless steel (316) foams of varying porosities have been made through powder metallurgy route using NH₄HCO₃ as a space holder. Green compacts of stainless steel powder with NH₄HCO₃ were sintered at two different temperatures: 1100 °C and 1200 °C. At higher sintering temperatures, neighboring stainless steel powders fused together to form polycrystalline grain structure with iron–chromium intermetallic phases segregated along the grain boundaries. Whereas, the fusion of neighboring stainless steel powders was limited around the particle–particle contact only when the green compacts were sintered at 1100 °C, which resulted in a larger amount of microporosities in the cell wall. These foams exhibited strain hardening behavior in the plateau region under compressive loading. The yield stress and the flow stress (at lower strain levels) of foams, sintered at 1100 °C were higher. But, the reverse is true for the flow stress at higher strain levels. The exponents and the coefficients of the power law relationships varied with sintering temperature and strain levels.     

High-temperature fatigue behaviour of a second generation near-γ titanium aluminide sheet material under isothermal and thermomechanical conditions

The high-temperature deformation behaviour of a second generation γ-TiAl sheet material with near-γ microstructure was characterised under tensile, creep, isothermal and thermomechanical fatigue (TMF) loading conditions. Test temperature ranged from 500 to 750 °C in isothermal tests and these temperatures were also used as minimum and maximum temperature of in-phase (IP) and out-of-phase (OP) thermomechanical fatigue tests. Under tensile loading, a ductile-to-brittle transition temperature (DBTT) of about 650 °C was observed. At this temperature the material experiences a temperature dependent change in the fracture morphology. Creep tests carried out in the temperature range from 650 to 800 °C under true constant stress conditions revealed a temperature and stress dependence of the Norton stress exponent n and the apparent activation energy for creep Q_app. With increasing temperature, isothermal fatigue life at constant strain amplitude decreased in vacuum, but increased in air indicating an abnormal (inverse) environmental effect. Under IP loading, fatigue is characterised by cyclic softening due to dynamic recrystallisation. OP loading drastically reduces fatigue life and turned out to be an extremely critical loading situation for γ-TiAl alloys.     

Water absorbent polyurethane composites derived from molasses and lignin filled with microcrystalline cellulose

Water absorbent polyurethane (PU) rigid composite foam was prepared using polyols derived from molasses and lignin filled with microcrystalline cellulose (MCC) powder with various particle sizes. By combining biomaterial components, preparation conditions were examined in order to obtain PU foams showing reliable water-adsorbing properties. Water absorbing capabilities, such as, water absorbing time, water retention in air as a function of time, and also mechanical properties in dry and wet state, were investigated. Rigid PU composite foams having equilibrium water retention ca. 1.0 g cm⁻³, maintain ca. 0.7 g cm⁻³ retention water in air after 24 h. Compression strength in the wet state was ca. 50 kPa and compression modulus ca. 1 MPa. MCC acts as a quick water absorbent in the initial stage of water immersion and PU matrix restrains a large amount of water for a long period.     

Cyclic and sustained loading behaviors of oxide/oxide Nextel™720/alumina composite with double edge sharp notch

This study investigated an oxide/oxide CMC consisting of Nextel?720 (meta-stable mullite) fibers in alumina matrix, N720/A, with 0°/90° fiber orientation having double edge sharp notch under sustained and cyclic loading conditions at 1200 °C in laboratory air environment. Monotonic tensile tests at 1200 °C were also conducted. Fracture surfaces were examined to analyze failure and damage mechanisms. Comparisons with counterparts from unnotched geometry showed N720/A is mildly sensitive to the sharp notch under monotonic tensile, creep and fatigue loading conditions. The ultimate tensile strength of the composite was reduced by about 15% in the presence of the sharp notch. The rupture strength of the sharp notched geometry was reduced by about 15% of unnotched geometry for a given rupture time. The fatigue strength was reduced by about 20% of unnotched geometry for a given number of cycles to failure. Deformation under cyclic loading condition had contributions both from fatigue and creep. Damage mechanisms were identical under cyclic and sustained loading conditions.