Mechanical testing of metallic foams for 3D model and simulation of cell distribution effects

Cellular materials have a bulk matrix with a larger number of voids named also cells. Metallic foams made by powder technology represent stochastic closed cells. The related inhomogeneity leads to a scattering of results both in terms of stress-strain curves and maximum strength. Scattering is attributed to relative density variations and local cell discontinuities and it is confirmed also in case of dynamic loading. Finite element simulations through geometrical models that are able to capture the void morphology (named “mesoscale models”), confirm these results and some efforts have been already done to quantify the relationship between shape irregularities and mechanical behavior. The aim of this paper is to present the dynamic characterization of an AA7075 closed cell material and to calibrate its mesoscale finite element model according to the related cell shape distribution. Specimens have been derived from a small ingot (45x45x100 mm) divided along sections so that morphological analysis and experimental tests have been carried out. Specimens extracted from a half of the ingot have been used for dynamic compression tests by means of a split Hopkinson bar, meanwhile specimens extracted from the other half of the ingot have been dissected for porosity distribution analyses carried out by means of image analysis. Stress-strain curves obtained from the mechanical tests have been discussed in terms of strain rate and statistical descriptors of the porosity. Successively a 3D-model of the specimen has been generated starting from the Voronoi algorithm, assigning as input the above-mentioned statistical distribution of the porosity. Due to the peculiarity of the cell morphology (e.g. single larger cells), stress-strain localization has been demonstrated as one of the reasons of the scattering found during the experiments. A material model, to reproduce the investigated foam mechanical behavior, has been calibrated. Despite the difference among experiments the material model is able to reproduce all of them. Difference between the model coefficients quantifies roughly the difference due to the local geometry of the cells.