Session: 17-01-01: Research Posters

Paper Number: 144145

144145 - 3d Phase-Field Modeling of Aluminum Foam 

Within the field of materials science, there has been considerable focus on the improvement of metallic foams, specifically those made from Al-Si alloys. These materials are renowned for their wide range of uses in different industries, due to their exceptional qualities. Al-Si alloy foams are notable for their low density, great mechanical strengths, exceptional energy absorption capabilities, and excellent thermal conductivity.

The advantageous characteristics of these materials arise from their unique porous microstructure, which combines the metallic properties of the base materials with a complex porous architecture. On the other hand, the mechanisms that control their creation, particularly the dynamics of bubble formation, development, and merging, provide major difficulties for both their investigation and production. Therefore, a comprehensive modeling technique is needed to accurately predict how the microstructure of the foam will change over time in order to customize its properties to suit specific applications.

This study presents a comprehensive multi-phase-field (PF) model that was developed in MATLAB. The model aims to accurately simulate the microstructural changes in Al-Si alloy foams. Using the Allen-Cahn equation, the model successfully combines the mechanics of interface dynamics, which include nucleation, growth of bubbles, and solidification, with diffusion-driven processes, which are modeled using the Cahn-Hilliard equation. Moreover, it integrates the Navier-Stokes equation in order to accurately depict the behavior of fluid and bubble dynamics within the molten alloy. The evolution equations of the PF model are solved by integrating a set of material constants that have been calibrated through experiments and molecular dynamics (MD) calculations.

An essential component of our research is the investigation of bubble coalescence, a phenomenon that significantly impacts the pore structure and, consequently, the mechanical strength of the resulting foam. Through this approach, we manipulate foam structures in order to achieve a closed-cell arrangement, which effectively prevents the fusion of bubbles and maintains the integrity of the porous structure through the process of solidification.

A multiscale computational framework that bridges the process, structure, property, and performance of metal foams will be established with the assistance of the phase field model that was developed with the purpose of predicting the microstructural evolution of metal foams during foaming processes. This framework will be established with the help of the phase field model. As a result, it has the potential to have a significant impact on the development of future metallic foams, which could result in the emergence of novel applications and advancements in the fields of material science and engineering.

Presenting Author: Chaimae Jouhari South Dakota State University

Presenting Author Biography: Graduate Research Assistant in the Department of Mechanical Engineering at South Dakota State University. Specialized in the fields of molecular dynamics and phase field modeling.

Authors:

Chaimae Jouhari South Dakota State University
Yucheng Liu South Dakota State University