Modeling and simulation of the quasi-static compressive behavior of Al/Cu hybrid open-cell foams

The development and manufacturing of hybrid metal foams through nanocrystalline electrodeposited metal coatings has recently received increased attention for their promise for tailored performance. The performance of nano-reinforced foams has been demonstrated and assessed experimentally. However, methods to numerically study and simulate the behavior of metal hybrid foams are not well established. Further, clear explanation of the mechanisms behind their unique behavior is still lacking. Finite element method approaches considering both coating and base material damage are used in this study to investigate the failure mechanisms and mechanical performance of nanocrystalline hybrid open cell foams at micro and macro scales. The numerical models agree well with experimental results and have provide insight into the behavior and failure mechanisms of hybrid foams. It was found that the low ductility capacity of nanocrystalline coatings can cause early fracture of composite ligaments and localized damage at the macro scale and thus reduce the load carrying capacity. The numerical results also indicate that the performance of hybrid foams can be enhanced by improving the ductility capacity of the coating material.