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Polyurethane (PUR) foam parts are traditionally manufactured using metallic molds, an unsuitable approach for prototyping purposes. Thus, rapid tooling of disposable molds using fused filament fabrication (FFF) with polylactic acid (PLA) and glycol-modified polyethylene terephthalate (PETG) is proposed as an economical, simpler and faster solution compared to traditional metallic molds or three-dimensional (3D) printing with other difficult-to-print thermoplastics, which are prone to shrinkage and delamination (acrylonitrile butadiene styrene, polypropilene-PP) or high-cost due to both material and printing equipment expenses (PEEK, polyamides or polycarbonate-PC). The purpose of this study has been to evaluate the ease of release of PUR foam on these materials in combination with release agents to facilitate the mulding/demoulding process.

PETG, PLA and hardenable polylactic acid (PLA 3D870) have been evaluated as mold materials in combination with aqueous and solvent-based release agents within a full design of experiments by three consecutive molding/demolding cycles.

PLA 3D870 has shown the best demoldability. A mold expressly designed to manufacture a foam cushion has been printed and the prototyping has been successfully achieved. The demolding of the part has been easier using a solvent-based release agent, meanwhile the quality has been better when using a water-based one.

The combination of PLA 3D870 and FFF, along with solvent-free water-based release agents, presents a compelling low-cost and eco-friendly alternative to traditional metallic molds and other 3D printing thermoplastics. This innovative approach serves as a viable option for rapid tooling in PUR foam molding.

Auxetics metamaterials show high performance in their specific characteristics, while the absolute stiffness and strength are much weaker due to substantial porosity. This paper aims to propose a novel auxetic honeycomb structure manufactured using selective laser melting and study the enhanced mechanical performance when subjected to in-plane compression loading.

A novel composite structure was designed and fabricated on the basis of an arrowhead auxetic honeycomb and filled with polyurethane foam. The deformation mechanism and mechanical responses of the structure with different structural parameters were investigated experimentally and numerically. With the verified simulation models, the effects of parameters on compression strength and energy absorption characteristics were further discussed through parametric analysis.

A good agreement was achieved between the experimental and simulation results, showing an evidently enhanced compression strength and energy absorption capacity. The interaction between the auxetic honeycomb and foam reveals to exploit a reinforcement effect on the compression performance. The parametric analysis indicates that the composite with smaller included angel and higher foam density exhibits higher plateau stress and better specific energy absorption, while increasing strut thickness is undesirable for high energy absorption efficiency.

The results of this study served to demonstrate an enhanced mechanical performance for the foam filled auxetic honeycomb, which is expected to be exploited with applications in aerospace, automobile, civil engineering and protective devices. The findings of this study can provide numerical and experimental references for the design of structural parameters.

The purpose of this paper is mainly to know: (1) the sound absorption coefficient of porous composite structures constituted by a new kind of lightweight ceramic foam and perforated plate; (2) the availability of an equivalent porous material model, recently proposed by the present author, to these composite structures in sound absorption.

A kind of lightweight ceramic foam with bulk density of 0.38–0.56 g·cm-3 was produced by means of molding, drying and sintering. The effect of stainless steel perforated plate on sound absorption performance of the ceramic foam was investigated by means of JTZB absorption tester.

The results indicate that the sound absorption performance could be obviously changed by adding the stainless steel perforated plate in front of the porous samples and the air gap in back of the porous samples. Adding the perforated plate to the porous sample with a relatively large pore size, the sound absorption performance could be evidently improved for the composite structure. When the air gap is added to the composite structure, the first absorption peak shifts to the lower frequency, and the sound absorption coefficient could increase in the low frequency range.

Based on the equivalent porous material model and the “perforated plate with air gap” model, the sound absorption performance of the composite structures can be simulated conveniently to a great extent by using Johnson-Champoux-Allard model.

This paper aims to understand the effect of extrusion conditions on the degree of foaming of polylactic acid (PLA) during three-dimensional (3D) printing. It was also targeted to optimize the slicing parameters for 3D printing and to study how the properties of printed parts are influenced by the extrusion conditions.

This study used a commercially available PLA filament that undergoes chemical foaming. An extrusion 3D printer was used to produce individual extrudates and print samples that were characterized using an optical microscope, scanning electron microscope and custom in-house apparatuses.

The degree of foaming of the extrudates was found to strongly depend on the extrusion temperature and the material feed speed. Higher temperatures significantly increased the number of nucleation sites for the blowing agent as well as the growth rate of micropores. Also, as the material feed speed increased, the micropores were allowed to grow bigger which resulted in higher degrees of foaming. It was also found that, as the degree of foaming increased, the porous parts printed with optimized slicing parameters were lightweight and thermally less conductive.

This study fills the gap in literature where it examines the foaming behavior of individual extrudates as they are extruded. By doing so, this work distinguishes the effect of extrusion conditions from the effect of slicing parameters on the foaming behavior which enhances the understanding of extrusion of chemically foamed PLA.

This study aims to present the numerical analysis of exergy transfer and irreversibility through the discrete filling of high-porosity aluminum metal foams inside the horizontal pipe.

In this study, the heater is embedded on the pipe’s circumference and is assigned with known heat input. To enhance the heat transfer, metal foam of 10 pores per inch with porosity 0.95 is filled into the pipe. In filling, two kinds of arrangements are made, in the first arrangement, the metal foam is filled adjacent to the inner wall of the pipe [Model (1)–(3)], and in the second arrangement, the foam is located at the center of the pipe [Models (4)–(6)]. So, six different models are examined in this research for a fluid velocity ranging from 0.7 to7 m/s under turbulent flow conditions. Darcy Extended Forchheimer is combined with local thermal non-equilibrium models for forecasting the flow and heat transfer features via metal foams.

The numerical methodology implemented in this study is confirmed by comparing the outcomes with the experimental outcomes accessible in the literature and found a fairly good agreement between them. The application of the second law of thermodynamics via metal foams is the novelty of current investigation. The evaluation of thermodynamic performance includes the parameters such as mean exergy-based Nusselt number (Nu_e), rate of irreversibility, irreversibility distribution ratio (I_DR), merit function (MF) and non-dimensional exergy destruction (I^*). In all the phases, Models (1)–(3) exhibit better performance than Models (4)–(6).

The present study helps to enhance the heat transfer performance with the introduction of metal foams and reveals the importance of available energy (exergy) in the system which helps in arriving at optimum design criteria for the thermal system.

The uniqueness of this study is to analyze the impact of discrete metal foam filling on exergy and irreversibility in a pipe under turbulent flow conditions.

Cement can be replaced to reduce the energy consumption and the environmental impact of cement. Also, foamed concrete can be used structurally in residential buildings to reduce weight and improve thermal insulation. To achieve these two goals, this paper aims to investigate the effect of basalt powder as a partial replacement of either cement or sand.

This paper investigates the effect of basalt powder as a partial replacement of either cement or sand on the mechanical properties of foamed concrete used to cast slabs. First, mechanical properties of foamed concrete are tested with and without replacement of basalt. Then, six slabs of different thicknesses and mixes are investigated. The thicknesses considered are 150- and 200-mm slabs. The three mixes used to construct these slabs are foamed concrete with no basalt powder, foamed concrete with replacement of 20% of cement by basalt powder and foamed concrete with replacement of 20% of sand by basalt powder. The flexural behavior of these slabs is investigated.

All the slabs failed in the commonly intended flexural mode. The results show that the basalt powder acted as a strong filler material in the foamed concrete mix based on mechanical properties and flexural behavior. The proposed foamed concrete slabs can be used structurally in residential buildings.

A natural waste material that can be used to promote energy efficiency and reduce emission is basalt. In this paper, basalt powder is suggested to be used due to its chemical composition that is similar to cement. Also, basalt powder is low in cost as it is waste, while basalt aggregate is prepared, and it is only used as filler in paved roads. Accordingly, basalt is partially used instead of cement to reduce the emission of carbon dioxide that results from the cement manufacturing. Also, it is used as a partial alternative to sand which can be considered as a new stronger source as filling material used in the production of concrete.

This study aims to elucidate the machining properties of low-cost expanded clay-reinforced syntactic foams by using different neural network models for the first time in the literature. The main goal of this endeavor is to create a casting machining-neural network modeling flow-line for real-time foam manufacturing in the industry.

Samples were manufactured via an industry-based die-casting technology. For the slot milling tests performed with different cutting speeds, depth of cut and lubrication conditions, a 3-axis computer numerical control (CNC) machine was used and the force data were collected through a digital dynamometer. These signals were used as input parameters in neural network modelings.

Among the algorithms, the scaled-conjugated-gradient (SCG) methodology was the weakest average results, whereas the Levenberg–Marquard (LM) approach was highly successful in foreseeing the cutting forces. As for the input variables, an increase in the depth of cut entailed the cutting forces, and this circumstance was more obvious at the higher cutting speeds.

The effect of milling parameters on the cutting forces of low-cost clay-filled metallic syntactics was examined, and the correct detection of these impacts is considerably prominent in this paper. On the other side, tool life and wear analyses can be studied in future investigations.

It was indicated that the milling forces of the clay-added AA7075 syntactic foams, depending on the cutting parameters, can be anticipated through artificial neural network modeling.

It is hoped that analyzing the influence of the cutting parameters using neural network models on the slot milling forces of metallic syntactic foams (MSFs) will be notably useful for research and development (R&D) researchers and design engineers.

This work is the first investigation that focuses on the estimation of slot milling forces of the expanded clay-added AA7075 syntactic foams by using different artificial neural network modeling approaches.

Natural good-quality sources of aggregates are depleting, whereas large amount of reclaimed asphalt pavement (RAP) is produced annually. Safe disposal and use of RAP in the cold in-place recycling (CIR) using foamed bitumen could be sustainable approach where milling and mixing operations are accomplished simultaneously. This will not only help in minimizing contamination (probability) and transportation cost but also reduces the carbon footprints. Therefore, this study aims to investigate the scope of RAP utilization up to 100% and further its effect on the behavior of reclaimed asphalt foamed bituminous mix.

Reclaimed asphalt foamed bituminous mix (FBM) is still a new technique. The evidence of performance of 100% recycled pavement (CIR) is only anecdotal and lacks in systematic guidelines and literatures. Foam binder coating around the aggregates is also a concern. Therefore, this study is mainly emphasized to investigate the scope of RAP use in the FBM up to 100%. RAP content is varied in each trial, i.e. 70, 85, 100 and 0% (only fresh aggregates), to make the FBM. RAP use and its effect on the behavior of FBM in terms of resilient modulus, variation in resilient modulus with curing, rutting performance and the potential of resistance against the moisture damage are addressed.

Considering the laboratory studies, it can be accomplished that mechanistic properties and performance of FBM are largely influenced by RAP material and portray less susceptible characteristics against the moisture damage. FBM containing 70% RAP content exhibits maximum resilient modulus. However, use of RAP up to 100% in FBM is satisfying the minimum required specification.

Overall, the study may be helpful to highway professionals and could generate another possible option of 100% RAP replacing fresh aggregates in the flexible pavements.

The purpose of this study was to introduce three-dimensional printing (3DP) of functionally graded sandwich foams (FGSFs). This work was continued by predicting the mechanical buckling and free vibration behavior of 3DP FGSFs using experimental and numerical analyses.

Initially, hollow glass microballoon-reinforced high-density polyethylene-based polymer composite foams were developed, and these materials were extruded into their respective filaments. These filaments are used as feedstock materials in fused filament fabrication based 3DP for the development of FGSFs. Scanning electron microscopy analysis was performed on the freeze-dried samples to observe filler sustainability. Furthermore, the density, critical buckling load (P_cr), natural frequency (f_n) and damping factor of FGSFs were evaluated. The critical buckling load (P_cr) of the FGSFs was estimated using the double-tangent method and modified Budiansky criteria.

The density of FGSFs decreased with increasing filler percentage. The mechanical buckling load increased with the filler percentage. The natural frequency corresponding to the first mode of the FGSFs exhibited a decreasing trend with an increasing load in the pre-buckling regime and an increase in post-buckled zone, whereas the damping factor exhibited the opposite trend.

The current research work is valuable for the area of 3D printing by developing the functionally graded foam based sandwich beams. Furthermore, it intended to present the buckling behavior of 3D printed FGSFs, variation of frequency and damping factor corresponding to first three modes with increase in load.

This paper aims to establish a lattice Boltzmann (LB) method for solid-liquid phase transition (SLPT) from the pore scale to the representative elementary volume (REV) scale. By applying this method, detailed information about heat transfer and phase change processes within the pores can be obtained, while also enabling the calculation of larger-scale SLPT problems, such as shell-and-tube phase change heat storage systems.

Three-dimensional (3D) pore-scale enthalpy-based LB model is developed. The computational input parameters at the REV scale are derived from calculations at the pore scale, ensuring consistency between the two scales. The approaches to reconstruct the 3D porous structure and determine the REV of metal foam were discussed. The implementation of conjugate heat transfer between the solid matrix and the solid−liquid phase change material (SLPCM) for the proposed model is developed. A simple REV-scale LB model under the local thermal nonequilibrium condition is presented. The method of bridging the gap between the pore-scale and REV-scale enthalpy-based LB models by the REV is given.

This coupled method facilitates detailed simulations of flow, heat transfer and phase change within pores. The approach holds promise for multiscale calculations in latent heat storage devices with porous structures. The SLPT of the heat sinks for electronic device thermal control was simulated as a case, demonstrating the efficiency of the present models in designing and optimizing SLPT devices.

A coupled pore-scale and REV-scale LB method as a numerical tool for investigating phase change in porous materials was developed. This innovative approach allows for the capture of details within pores while addressing computations over a large domain. The LB method for simulating SLPT from the pore scale to the REV scale was given. The proposed method addresses the conjugate heat transfer between the SLPCM and the solid matrix in the enthalpy-based LB model.