Micro-structural Deformation Field Analysis of Aluminum Foam using Finite Element Method and Digital Image Correlation

Porous materials especially closed-cell metallic foams play important roles among novel materials because of their good characteristics e.g. high strength to weight ratio and crashworthiness. On the other hand, mechanical behavior determination and detailed characterization are essential in efficient manipulation and material tailoring. In the present research especial hybrid experimental-numerical approach is used for aluminum foam behavior determination as to the main goal, i.e. continuous deformation field measurement using digital image correlation (DIC) and finite element analysis (FEA) on porous specimen’s surface.  To overcome the 3D modelling problem of closed-cell foams structure, we present the method based on CT-scan and digital optic microscope imaging combination. In the experimental part of the study, aluminum foams and proper specimens are manufactured, and then high-resolution digital imaging and illumination setup are employed. Finally, the deformation field is obtained using DIC. On the other hand, measurement verification and DIC parameters optimization processes are conducted using ABAQUS 2019 with comprehensive mesh independency study and response surface methodology (RSM) respectively as major research achievement. Finally, correlation equations based on high regression models are obtained. Using detailed geometrical micro-model and optimal DIC parameters yields to good numerical-experimental accordance. The novel approach of combined CT and digital microscope imaging instead of industrial micro-CT lowered imaging costs while yielded to accurate numerical results.