Design of a novel x-ray CT in situ experiment for imaging 3D deformation of aluminum foam materials

Open-cell metallic foams show excellent potential for lightweight load-bearing structural applications, electrodes in energy-storage devices, biomedical implants, and heat exchangers, to name a few. A key aspect in efficient and streamlined deployment of aluminum foams for these applications lies in accurate characterization of their 3D mechanical performance. The purpose of this thesis is to describe the development of a novel experiment that couples X-ray computed tomography (CT) and in situ mechanical testing- which enables 3D observations of deformation and failure of aluminum foams during compressive loading. The 3D image data from these experiments is converted into detailed finite element (FE) models, enabling virtual testing of aluminum foams in a computational framework. The objectives of this study include: 1) development of an axial load-frame that will adopt to an existing X-ray CT scanner at the Utah Composites Laboratory; 2) generation of 3D X-ray CT image data during quasi-static compression of aluminum foam; 3) generation of a detailed FE model of an as-measured aluminum foam, and 4) a direct comparison of data from the in situ experiment and the FE simulation. The ultimate goal of this study is to provide new insight into the deformation and failure of open-cell aluminum foam, which will eventually allow aluminum foam to be deployed in practical industrial applications.