Investigation of cell shape effect on the mechanical behaviour of open-cell metal foams

The mechanical behaviours of metal foams greatly depend on their cell topology, including cell shape, cell size etc. as well as relative density and material properties of the cell wall. However, the cell shape effect on the mechanical behaviours of such materials appears to be ignored in previous research. In this paper, both analytic and finite element models are developed and employed to investigate the effect of cell shape on the mechanical behaviour of open-cell magnesium alloy (AZ91) foams under compression, including deformation modes and failure modes. For numerical modelling, both two-dimensional (2-D) and three-dimensional (3-D) finite element models are developed to predict the compressive behaviours of typical open-cell metal foams and capture the deformation modes and failure mechanisms. Two typical cell shapes i.e. cubic and diamond are taken into consideration. To validate these models, the analytic and numerical results are compared to the experimental data. Both the numerical and experimental data indicate that the cell shape significantly affects the compression behaviour of open-cell metal foams. In general, numerical results from the three-dimensional solid-element model show better agreement with the experimental results than those from other finite element models.