Introduction
Open-cell metal foams—including stochastic foams and lattice structures—are structural-material systems comprised of interconnected ligaments (referred to herein as struts) forming a hierarchical structure that includes the scales of the sub-strut (e.g., grain structure), strut, cell, and bulk foam. The reported relative density (or equivalently, volume fraction) of open-cell metal foams can range from 1% upwards to approximately 40%, depending upon the manufacturing technique used to produce the foam [
1]. Due to their open-cell porous structure and ultra-low density, these structural materials have been used in a wide variety of multi-functional applications [
2‐
4]. For example, in addition to serving as light-weight, load-bearing structures, open-cell metal foams can serve concurrently as electrodes for energy-storage devices [
5], as hosts for newly generated bone and blood vessels in biomedical implants [
6‐
8], or as impact absorbers and noise insulators for advanced high-speed ground transportation [
4], to name a few.
There have been many efforts in the literature to model open-cell metal foams to enable prediction of their mechanical (e.g., [
9,
10]) and thermal-fluid (e.g., [
11‐
13]) properties. Techniques for generating 3D models of open-cell metal foams can be classified into two general categories: (1) conversion of real data from, e.g., X-ray computed tomography (“CT”) measurements [
9,
14‐
20] and (2) generation of synthetic foams to represent both periodic unit-cell structures and stochastic foams. In the second case, the most common geometries used in modeling periodic unit-cell foams are the tetrakaidecahedron (or Kelvin’s cell, e.g., [
10]) and the Weaire-Phelan cell [
21], which have been compared quantitatively to the geometrical features in stochastic foams [
22]. To model stochastic foams, researchers have implemented a variety of techniques, including the application of Voronoi tessellations [
12,
23] and spherical packing followed by Voronoi decomposition [
24], which have resulted in very realistic foam structures. Surface evolver [
25] is a software that can be used to generate realistic foam structures based on energy minimization reminiscent of the foaming process and has been used by a number of researchers to generate stochastic-foam models [
13,
26,
27]. A relatively recent software, called GeoDict, has a FoamGeo module that allows for generation of both periodic unit-cell and stochastic foam structures and has been used by a number of researchers (e.g., [
28]).
Despite the growing interest in modeling open-cell metal foams, all of the modeling efforts described above have resolved the foams to the cell level, treating each strut as a material continuum. In fact, to the authors’ knowledge, there have been no modeling efforts of open-cell metal foams that incorporate grain structure. Nonetheless, some experimental studies have suggested that grain structure could play an important role in determining the mechanical response of open-cell foams. For example, work by Goussery et al. [
29] found that the yield strength of non-oxidized samples of open-cell, hollow-strut nickel foam decreased with increasing grain size up to the thickness of the strut wall. Additionally, Plumb et al. [
30] recently mapped the 3D grain structure of open-cell aluminum foam and found that grain sizes were on the order of the size of the strut, suggesting that size effects due to grain structure could influence mechanical response of the foams.
In light of the above motivation, the aim of this paper is to describe a recent software development that enables generation of realistic open-cell foam models that are resolved to the scale of individual grains. The new capability has been implemented as a filter within the widely used, open-source software DREAM.3D [
31]. Whereas, DREAM.3D conventionally enables instantiation of fully-dense, multi-phase material microstructures, the new filter now enables instantiation of open-cell polycrystalline foams. The foam geometry at the cell level can either be fully synthetic or based on CT data (on which grain structure is overlaid). The filter (and by extension, DREAM.3D) allows user control over pore size, strut cross-section shape, strut thickness and thickness variability, grain size, and crystallographic texture, among other attributes. The filter provides a new and powerful tool to investigate performance of open-cell polycrystalline foams by accounting for the hierarchical structure of the foam down to the grain scale.
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