Cubic elasticity of porous materials produced by additive manufacturing: experimental analyses, numerical and mean-field modelling

• Published in: Archives of Civil and Mechanical Engineering Vol. 24; no. 1; p. 34
• Main Authors: Kowalczyk-Gajewska, Katarzyna, Maj, Michał, Bieniek, Kamil, Majewski, Michał, Opiela, Kamil C., Zieliński, Tomasz G.
• Format: Journal Article
• Language: English
• Published: London Springer London 03.01.2024; Springer Nature B.V
• Subjects: 3-D printers; Additive manufacturing; Anisotropy; Civil Engineering; Digital imaging; Elastic anisotropy; Elastic properties; Engineering; Image compression; Manufacturing; Mathematical models; Mechanical Engineering; Mechanical properties; Microstructure; Morphology; Original Article; Polymers; Pore size distribution; Porous materials; Spheres; Stiffness; Strain; Structural Materials; Symmetry; Three dimensional printing; Pore configuration; Elasticity; Micro-mechanics; Additive manufacturing; Anisotropy
• ISSN: 2083-3318; 1644-9665; 2083-3318
• DOI: 10.1007/s43452-023-00843-z

Although the elastic properties of porous materials depend mainly on the volume fraction of pores, the details of pore distribution within the material representative volume are also important and may be the subject of optimisation. To study their effect, experimental analyses were performed on samples made of a polymer material with a predefined distribution of spherical voids, but with various porosities due to different pore sizes. Three types of pore distribution with cubic symmetry were considered and the results of experimental analyses were confronted with mean-field estimates and numerical calculations. The mean-field ‘cluster’ model is used in which the mutual interactions between each of the two pores in the predefined volume are considered. As a result, the geometry of pore distribution is reflected in the anisotropic effective properties. The samples were produced using a 3D printing technique and tested in the regime of small strain to assess the elastic stiffness. The digital image correlation method was used to measure material response under compression. As a reference, the solid samples were also 3D printed and tested to evaluate the polymer matrix stiffness. The anisotropy of the elastic response of porous samples related to the arrangement of voids was assessed. Young’s moduli measured for the additively manufactured samples complied satisfactorily with modelling predictions for low and moderate pore sizes, while only qualitatively for larger porosities. Thus, the low-cost additive manufacturing techniques may be considered rather as preliminary tools to prototype porous materials and test mean-field approaches, while for the quantitative and detailed model validation, more accurate additive printing techniques should be considered. Research paves the way for using these computationally efficient models in optimising the microstructure of heterogeneous materials and composites.