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Numerical simulation of particle infiltration for the hybrid-foam manufacturing process

Thursday (08.10.2020)
14:00 - 14:20

In the context of lightweight construction, materials like metal foams [1] and metal/polymer hybrid structures [2] show promising properties. The microstructure of those materials influences their effective properties and thus the manufacturing process, whereof the microstructure results is of great interest. The manufacturing of metal/polymer hybrid foams is investigated via numerical simulations. This can be achieved by filling the pores of the foam with some granulate e.g. poly styrol, which is then sintered to obtain the hybrid foam. In such a process, the microstructure is influenced by the particle distribution resulting from the granulate infiltration. A simulation method for the particle infiltration was developed. The coupling of fluid flow with rigid body particles is performed based on the distributed Lagrange multiplier (DLM) method [3] and the phase-field method. The latter enables the consideration of complex geometries without a body-fitted mesh and offers an eulerian framework for particulate flows avoiding the necessity of re-meshing. This leads to a computationally cheap method for the present problem. A collision model for contact between particles and arbitrary geometries based on the phase-field method is introduced and complements the present method in order to handle collisions with the foam structure. In the talk, the numeric method will be introduced and simulation studies of particle infiltration based on it will be presented.



[1] T. D. Claar, C.-J. Yu, I. Hall, J. Banhart, J. Baumeister, and W. Seeliger. Ultra-lightweight aluminum foam materials

for automotive applications. SAE transactions, pages 98-106, 2000.

[2] M. Mieszala, M. Hasegawa, G. Guillonneau, J. Bauer, R. Raghavan, C. Frantz, O. Kraft, S. Mischler, J. Michler,

and L. Philippe. Micromechanics of amorphous metal/polymer hybrid structures with 3d cellular architectures: size

effects, buckling behavior, and energy absorption capability. Small, 13(8):1602514, 2017.

[3] N. Sharma and N. A. Patankar. A fast computation technique for the direct numerical simulation of rigid particulate

ows. Journal of Computational Physics, 205(2):439-457, 2005.

Martin Reder
Karlsruhe University of Applied Sciences