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Construction and Building Materials: Shunze Cao, Yuwu Zhang, Yang Lu
Construction and Building Materials: Shunze Cao, Yuwu Zhang, Yang Lu
h i g h l i g h t s
The GBs can increase the mechanical properties and energy-absorption capacity of polymer foams.
The novel simulation strategy enables to model both cells and GBs explicitly.
The numerical predictions show good agreements with experimental and analytical results.
The numerical results indicated the hardening stress increased with the decrease of GBs size.
a r t i c l e i n f o a b s t r a c t
Article history: Particle reinforced (PR) polymer foams are promising materials for lightweight structures. In this
Received 14 July 2020 research, compression tests were conducted on glass beads (GBs) reinforced linear low-density polyethy-
Received in revised form 12 December 2020 lene (LLDPE) foams. The experimental results indicated that embedding GBs could increase the yield
Accepted 15 December 2020
strength, elastic modulus and energy absorption capacity of bulk material. Analytical predictions of
Available online 7 January 2021
GBs reinforced foams were also used to compare with experimental results. To investigate the microme-
chanics of neat foams and glass PR foams under compression, the finite element (FE) simulations were
Keywords:
conducted. The analysis of neat foams indicated that the strain localization occurred at right and left sides
GBs reinforced polymer foams
Three-dimensional finite element analysis
of hollow cells during the plateau stage. For GBs reinforced foams, the foam matrix around the particle
Analytical predictions reinforcements was nearly densified while the foam matrix without GBs remained undensified due to
Parametric study the stabilisation of glass particles. The parametric studies reasonably explained why hardening stress
of foam increases with the decrease of particle size.
Ó 2020 Elsevier Ltd. All rights reserved.
https://doi.org/10.1016/j.conbuildmat.2020.122062
0950-0618/Ó 2020 Elsevier Ltd. All rights reserved.
S. Cao, Y. Zhang and Y. Lu Construction and Building Materials 275 (2021) 122062
increased. Additionally, the efficiency of energy absorption and 2. Materials and manufacturing
plateau stress also increased as the VF of particles increased to
2%, but this trend was reversed when the VF of reinforcements The currently studied PR polymer foams are composed of poly-
was over 20%. The similar trends were also found when embedding mer foam matrix and porous glass beads (i.e. particle reinforce-
the TiB2 and Y2 O3 particles [14,15]. For the Al alloy foams, which ments). The foam matrix, which is made from LLDPE powder
have shown better mechanical and thermal properties than the supplied by Dalian Bona Biological Technology Co., Ltd., contains
neat Al foams [16], the ceramic particles were also embedded into two parts, i.e. LLDPE polymer (solid region) and spherical hollow
the foam matrix for reinforcing purposes. However, the reinforcing cells (voids within foam). The LLDPE powder is defined by a density
effect was not ideal. The foams became more brittle, and stress of qs ¼ 0:935 g=cm3 , an elastic modulus of Es ¼ 450 MPa, and a
fluctuations in the plateau region was more obvious compared to yield strength of rs ¼ 27:5 MPa. The recycled GBs with parent
the neat Al alloy foams [17–19]. The phenomena could be caused material density of qp ¼ 0:35g=cm3 are supplied by the Quietstone
by the inhomogeneous microstructures after embedding particles.
UK Ltd. Based on the random sampling, the size of GBs have the
Unlike the unstable mechanical properties of particles rein-
size dp ranging from 1.41 mm to 2.25 mm after sieving by a mesh
forced metal foams, polymer foams reinforced by nano-particles
with 2.5 mm circular pores. The particle size follows a normal dis-
or micro-particles showed apparent reinforcing effects. Jayavard-
tribution dp ~ N (dpm =1.75 mm, l2pm =0.0408 mm2) with dpm and l2pm
han and Doddamani [20] developed the glass micro-PR high den-
sity polyethylene foams. The enhancements of yield strength, and representing the mean size and standard deviation, respectively, as
elastic modulus were obvious compared to the non-reinforced shown in Fig. 1 (a). Fig. 1 (b) plots the compressive force versus dis-
HDPE foams. For the nanoscale particles, the reinforcements placement relationship of a single glass particle with the size of
played an important role in the modification of the foam dp = 1.75 mm under uniaxial quasi-static compression. The force
microstructures. Saha et al. [21] embedded TiO2 nanoparticles into fluctuations of GBs under compression could be caused by the
polyurethane foams. The compressive strength and elastic modu- nonuniform local and brittle damage within the internal porous
lus increased due to the stabilisation of cells wall and the modifi- structure before the catastrophic collapse. According to the curve
cation of cells size. fitting on the compressive response of the single particle via
The glass beads used in this research were made from recycled numerical calculations (see the Section 4.2 for FE analyses), the
glass. The beads were sintered and expanded at a temperature of compressive strength of the parent material of glass particle is cal-
750 °C with the benefits of lightweight, sound absorption, fire ibrated to be rp 9.87 MPa. Based on the assumption of elastic
proofing, and thermal insulation [22]. Aygün and McCann [23] Herzian contact between the glass particle and the loading
investigated the structural performances of recycled glass bead machine [32,33], the elastic modulus of this particle can be esti-
panels. The results indicated that the recycled glass-based struc- mated as Ep = 387.37 MPa using the following equation
tures showed the potential applications in both building structures 0:5
4dp s 1:5
and noise barriers in highway due to the high tension, bending Ep ¼ ð Þ ð1Þ
resistances, and the excellent sound absorption capabilities. 3PE ð1 mp Þ 2
To understand the micromechanics of foams, several numerical where P E and s denote the compressive force and displacement of
studies have employed the Laguerre and Voronoi tessellation tech- glass particles, respectively, as shown in Fig. 1 (b). mp is the Poisson’s
niques to build the 3D FE models of foam materials, which repli-
ratio of glass particles, which is calibrated to obtain mp = 0.
cated the internal microstructures of foams well [24–27]. Ghazi
The manufacturing methodology of the GBs reinforced polymer
and his co-authors established 3D FE models of foams based on
foams is described as follow. The polymer powder, glass particles
the X-ray CT technics, and the integrated Representative Volume
as well as the azodicarbonamide blow agent (supplied by the
Elements (RVEs) computation strategies, which showed accurate
Shuntai Technology CO. Ltd.) were mixed with the required pro-
predictions of mechanical responses and deformation mechanisms
portions and stirred in a blender for 5 min. The volume fractions
of closed-cell foams [28–30]. Cho et al. [31] created a 3D finite ele-
of polymer polymer (F) and glass particle reinforcements (f) were
ment model to understand the tensile responses of GBs reinforced
defined to quantify the relative amount of their constituents to
foams. The glass particles were inserted into the homogenous
the bulk material. Hence, F ¼ V p =V T and f ¼ V f =V T , where V p , V f
matrix randomly. The FE analysis suggested that the yielding of
and V T represent the volume of polymer polymer, the volume of
foam matrix occurred at the beginning of the particle breakage.
glass particle reinforcements and the volume of bulk specimen,
However, the previous investigations about the interactions
respectively. In order to demould, the release agent was spread
between hollow cells and particle reinforcements during deforma-
on surfaces of a mild steel mould where the mixture was then
tion were limited. Owing to the stochastic nature of the internal
evenly loaded from the blender with the speed of 500r/min in
structure of foam matrix, it might be over idealized to regard the
the room temperature. Then, the steel mould with the mixture
foams as the homogeneous matrix. In this study, the 3D FE models
was heated in the sealed mould at 210 °C for an hour, followed
of GBs reinforced foams were built to predict the compressive
by a cooling process at the room temperature for 24 h.
responses under uniaxial quasi-static compressive tests. The hol-
Due to the fact that there is insufficient polymer powder to pro-
low cells and glass particles were created explicitly in FE models
duce a foam specimen when F<0.214 and the density is too high
to understand the complex interactions during compression.
for specific applications when F>0.428, four types of neat foam
The outline of this paper is described as follow. The characteri-
specimens with F = 0.214, 0.267, 0.321 and 0.428 were manufac-
sations of foam and glass particles and the manufacturing method
tured for experimental measurements. In addition, six types of
are introduced in the Section 2; the experimental methodology is
GBs reinforced foams with the combinations of F = 0.214, 0.321
reported in the Section 3; the FE models of GBs reinforced foams
and f = 0.1, 0.2, 0.3 were also manufactured. It should be noted that
that are built based on the modelling strategy is described in the
a homogenous porous foam was unable to be achieved for f>0.3.
Section 4; the results obtained by experiments, analytical models,
In order to analyze the internal porous architectures of foams,
and FE analyses are analysed in the Section 5.
the two-dimensional images of sectional neat foam specimens by
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S. Cao, Y. Zhang and Y. Lu Construction and Building Materials 275 (2021) 122062
Fig. 1. (a) Normal distribution of particle sizes, and (b) the experimentally measured and numerically predicted compressive force as a function of displacement for a single
glass bead particle.
a bandsaw (Rikon 10–305) were obtained using an optical micro- of foam specimen. There were three repeats for each type of poly-
scope (OLYMPUS BX53M). The microscopic images of the neat mer foam.
foams at four different polymer volume fractions are shown in
Fig. 2, which indicated the internal characteristic of closed-cell. 4. Finite element modelling and simulation
The typical schematic of the internal architecture is drawn in
Fig. 2 (c) where e is the clear distance between two adjacent cells, Finite element calculation was conducted to predict the uniax-
and Dc the cell size. The images of sectioned neat polymer foams ial compressive behavior and to investigate the reinforcing mech-
with different F obtained from the optical microscope reveal the anism of glass particles within polymer foams. The finite element
characteristics of close cells, as shown in Fig. 2 (c) and (f). In order modeling can be explained by the following three parts.
to understand the distribution of cell size, the cell sizes were mea-
sured, and the distribution diagram of each type of neat foam is 4.1. Generation of geometry of the foam matrix
plotted in Fig. 2 as well. With the increase of F, the cell size
decreases, e.g. the cell sizes are in the range of 0.464 ~ 3.824 mm For the foam geometry, both porous glass particles and cells
for the foam with F = 0.214 while the size are 0.659 ~ 2.356 mm within the foam specimen were explicitly modelled as spheres
for the foam with F = 0.267. The data in the diagrams suggests that and inserted into the foam matrix randomly. Based on the
the distribution of cell size of foams can be regarded as the normal microstructural analysis in Section 2, it was assumed that both
distribution, i.e. Dc ~ N (Dcm , l2cm ), where Dcm is the mean size of the particle size and cell size followed the normal distribution of
cells and l2cm represents the variance. The distribution parameters dp ~ N (dpm , l2pm ) and Dc ~ N (Dcm , l2cm ), respectively. The following
of hollow cells at different polymer volume fractions have been algorithms were used to arrange the locations of spherical inser-
summarized in Table 1. tions, namely the glass particles and the hollow cells.
The microscopic image of sectioned PR foam with F = 0.321 and The locations of spherical insertions in the cubic domain satisfy
f = 0.2 is shown in Fig. 3 (a). It indicates that the presence of glass two conditions
particle reinforcements within foam matrix does not influence the (1) The coordinate (X, Y, Z) of spherical centers follow the rela-
cell size significantly. Fig. 3 (b) shows an X-ray computed tomogra- tion below
phy (CT) image of a foam with F = 0.321 and f = 0.2. The black
region represents the foam matrix, and the grey spheres represent ðX; Y; Z Þ 2 fðX; Y; Z Þjr 6 X 6 l r; r 6 Y 6 l r; r 6 Z 6 l r g ð2Þ
glass particles. From the CT image shown in Fig. 3 (b), the glass par- where r is radius of a spherical insertions.
ticles are uniformly distributed within foam matrix, which guaran- (2) All the spheres are independent and do not overlap with
tees the repeatability of the compression tests on PR foams. each other
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2 2 2
X i X j þ Y i Y j þ Z i Z j r i þ rj þ e; 8i; j 2 n; i–j ð3Þ
th
3. Experimental methodology where i and j denote parameters associated with the i and the jth
sphere, respectively, and e is the mean distance between any two
In order to characterize the mechanical properties of the GBs adjacent cells, which has been listed in Table 1 for foams with dif-
reinforced polymer foams, quasi-static uniaxial compression was ferent volume fractions. n the number of all spheres.
performed based on the method described by ASTM 1621-04a The geometry of GBs reinforced polymer foam was generated
[34]. Both the neat foam and GBs reinforced foam specimens were via a Python script in environment of the finite element package
cubic with the edge length of l = 50 mm. The compressive ABAQUS Ò [35], and the geometry generation can be divided into
responses of the specimens were measured by a universal screw- three steps which are schematically illustrated in Fig. 4. The foam
driven testing machine (MTS815) with a constant loading rate of matrix was firstly created (Fig. 4 (a)), then the spherical insertions
5 mm/min. The compressive force PF and displacement Dl of foams that have the identical size with the glass particles and cells were
were detected by the 50kN load cell and the linear variable differ- inserted into the cubic foam matrix randomly (Fig. 4 (b)). Next, the
ential transformer (LVDT), respectively. Hence, the engineering inserted spheres were removed from the foam domain via a Boo-
compressive stress and strain can be calculated as r ¼ P F =A and lean operation (Fig. 4 (c)), and the hollow spheres representing
e ¼ Dl=l, respectively, where A is the original cross-sectional area particles were created and inserted into the same location where
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S. Cao, Y. Zhang and Y. Lu Construction and Building Materials 275 (2021) 122062
Fig. 2. The corresponding distributions of particle size for each type of neat foam are shown in (a), (b), (d), and (e), respectively. The microscopic images of neat polymer
foams with F = 0.214, 0.267, 0.321, 0.428 are shown in (c), and (f), respectively.
the solid spheres occupied (Fig. 4 (d)). The Cartesian coordinate It is known that there are plenty of cells with different size
system employed in the numerical simulation is shown in Fig. 4 scales among polymer foams, thus the FE modelling considering
as well, i.e. the compressive orientation of foams is parallel to Z all cells could be computationally expensive. Fig. 5 shows the
axis, both X axis and Y axis are perpendicular to the loading microscopic comparison of neat foam specimen with F = 0.321
orientation. before compression and at the nominal compressive strain of
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S. Cao, Y. Zhang and Y. Lu Construction and Building Materials 275 (2021) 122062
Fig. 3. The (a) microscopic image and (b) CT image of PR foam with F = 0.321 and f = 0.2.
5
S. Cao, Y. Zhang and Y. Lu Construction and Building Materials 275 (2021) 122062
where h is the shape factor of yield surface, which can be calculated calculations, the Poisson’s ratio of polymer foam was assumed as
from the plastic Poisson’s ratio v p _p
0. In this study, we use the equivalent plastic strain rate e to
9 1 2v p describe the plastic deformation
h2 ¼ ð6Þ
2 1 þ vp
where rf denotes the initial yield stress in uniaxial compression, where r denotes Cauchy stress tensor, rcf uniaxial compressive
and pf the initial yield stress in hydrostatic compression. In the FE stress, and e_ pl plastic strain rate.
6
S. Cao, Y. Zhang and Y. Lu Construction and Building Materials 275 (2021) 122062
Fig. 6. (a) The normal distributions of cells size for the neat foams with F = 0.267, F = 0.214, and the inserted cells. (b) The cells were inserted into the foam matrix with
F = 0.267 to create the foam matrix with F = 0.214.
Z utm
W cr ¼ rt dut ð9Þ
0
where utm is the crack opening while the tensile stress rt decreases
to 0. In FE calculations, the meshes were deleted via the technique Fig. 8. The degradation of tensile stress against the crack-opening displacement.
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S. Cao, Y. Zhang and Y. Lu Construction and Building Materials 275 (2021) 122062
of element deletion when the deformation of element reached to Fig. 9 (b) indicates that the analytical predictions obtained from
utm to avoid excessive mesh distortion. the Gibson-Ashby model present a good agreement with the exper-
imental measurements. As for the elastic modulus Ef of the foams,
Gibson and Ashby [38] suggested that Ef can also be linked with q,
5. Results and discussion expressed as follow
Fig. 9. (a) The experimental measurements of uniaxial compressive responses of neat polymer foams with different F. The comparisons of experimental measurements and
analytical models of (b) yield strength and (c) elastic modulus with different F.
8
S. Cao, Y. Zhang and Y. Lu Construction and Building Materials 275 (2021) 122062
Fig. 10. The experimental measurements of uniaxial compressive responses of polymer foams of (a) F = 0.214 and (b) F = 0.321 at selected f. The comparisons of experimental
measurements and analytical models of (c) yield strength and (d) elastic modulus as functions of f.
Table 2
The elastic modulus and yield strength of PR foams measured in experiment.
9
S. Cao, Y. Zhang and Y. Lu Construction and Building Materials 275 (2021) 122062
rp rf 0:05rp Es q2
rc ¼ ð13Þ rc ¼ ð14Þ
ð1 f Þrp þ f rf 0:05fEs q2 þ ð1 f Þrp
where rc , rp , and rf represent the yield strengths of GBs reinforced It indicates that the analytical prediction of yield strength has a
foams, particle reinforcements, and foam matrix, respectively. The good agreement with experimental measurements at low f. Isai
yield strength of GBs reinforced foam can be further evaluated as and Cohen [40] proposed an analytical model (see Eq. (15)) for pre-
follow by substituting Eq. (10) into Eq. (13) dicting the elastic modulus of GBs reinforced foams
Fig. 13. Comparisons of engineering stress–strain curves of foams with polymer volume fraction of 0.214 and f = 0, f = 0.1, and f = 0.2 between experiments and simulations.
10
S. Cao, Y. Zhang and Y. Lu Construction and Building Materials 275 (2021) 122062
" #
f forcements to improve the compression resistance. The FE simula-
Ec ¼ 1 þ 1=3
Ef ð15Þ tion in Section 5.2.2 suggests that the foam starts to be densified
m=ðm 1Þ f
when upper and lower surfaces of the large hollow cells start to
with contact with each other, corresponding to the compressive strain
of 0.5 (Point B in Fig. 11); the foams can be regarded to be fully
m ¼ Ep =Ef ð16Þ
densified and particles are crushed when upper and lower surfaces
where Ec is the elastic modulus of GBs reinforced foam. are in full contact, corresponding to the compressive strain of 0.8
In addition, another analytical prediction, which considers the (Point C in Fig. 11). Hence, the absorbed energy per unit volume
R 0:5
micromechanics, suggested by Halpin and Tsai [41] is given as W 1 , W 1 ¼ 0 rde, is calculated to characterize the influence of
follow particle stabilization; the absorbed energy per unit volume of
R 0:8
1 þ dgf W 2 , W 2 ¼ 0:5 rde, is used to characterize the influence of particles
Ec ¼ Ef ð17Þ
1 gf crushing.
To understand the effect of particle reinforcements on the
with
energy absorption capacity of polymer foams, the absorbed energy
Ep =Ef 1 per unit volume of GBs reinforced foams W 1r ð0 6 e 6 0:5Þ and
g¼ ð18Þ
W 2r ð0:5 6 e 6 0:8Þ are normalized by the absorbed energy per
Ep =Ef þ d
unit volume of neat foams W 1p ð0 6 e 6 0:5Þ and
where, d is a non-dimensional parameter dependent on the geome- ^ 1 ¼ W 1r =W 1p
W 2p ð0:5 6 e 6 0:8Þ, respectively, expressed as W
try of reinforcement. Specifically, d ¼ 2 for the spherical particle
and W ^ 2 ¼ W 2r =W 2p . Fig. 12 (a) and (b) plot the W
^ 1 and W
^ 2 as
[42]. As plotted in Fig. 10 (d), both the two analytical models have
good agreements with the experimental measurements, especially a function of particle volume fraction at polymer volume fraction
at low particle volume fractions, i.e. f 6 0:2. of 0.214 and 0.321, respectively. The normalized energy absorption
of GBs reinforced foams is normally higher than that of the neat
5.1.3. Energy absorption capacity foams for the same volume fractions, which suggests the particle
Normally, the neat foams enable to absorb most energy via the reinforcement enables to improve the energy absorption capacity
deformation of hollow cells before foam densification. For the GBs of foams. However, the foams with F = 0.321 and f = 0.1 are the
reinforced foams, the cells can be stabilized by the particle rein- exceptions due to the earlier crushing of particle reinforcements
Fig. 14. FE predictions of deformation process of the neat polymer foam with F = 0.214 under uniaxial compression.
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S. Cao, Y. Zhang and Y. Lu Construction and Building Materials 275 (2021) 122062
than crushing the hollow cells, as discussed in Section 5.1.2. In compressive stress when e P 0:4 for the foams with f = 0.2. Signif-
addition, the particle reinforcements, especially at lower particle icant mesh distortion of foam matrix occurred when e>0.5, which
volume fraction (f = 0.1), have more significant enhancement on resulted in the end of calculations. The fluctuation of curves
the energy absorption capacity for foams with F = 0.214 than the obtained from FE predictions for the foam with f = 0.1 and
foams with F = 0.321. f = 0.2, which were highlighted by the dashed circles, could be
caused by the crushing of glass particles.
5.2. Finite element simulation of polymer foams
Fig. 15. FE predictions of deformation process of the polymer foam with F = 0.214 and f = 0.2 under uniaxial compression.
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S. Cao, Y. Zhang and Y. Lu Construction and Building Materials 275 (2021) 122062
Fig. 16. The 3D FE predictions of deformation process of glass particles with the foam matrix of F = 0.214 and f = 0.2 under uniaxial compression.
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S. Cao, Y. Zhang and Y. Lu Construction and Building Materials 275 (2021) 122062
Fig. 18. The compressive responses of particles with (a) dpm = 1.40 mm and (b) dpm = 2.00 mm.
6. Conclusions of matrix material. In the future studies, we will compare the cur-
rent strategy with RVE method about the computational expenses
The uniaxial compressive behaviors of neat polymer foams and and accuracy.
glass GBs reinforced polymer foams were studied through analyt-
ical analyses, FE analyses, and experimental measurements. The
internal porous microstructures of polymer foams were examined Declaration of Competing Interest
via the optical microscopes and X-ray CT scanning, which provided
a rational reference for selecting appropriate modelling parameters The authors declare that they have no known competing finan-
of the FE analysis. cial interests or personal relationships that could have appeared
The experimental measurements have demonstrated that to influence the work reported in this paper.
embedding glass particles can increase the macroscopic elastic
modulus, yield strength and capacity of energy absorption com-
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