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This study aims to make foamed polylactic acid (PLA) structures with different densities by varying deposition temperatures using the material extrusion (MEX) additive manufacturing process.

The extrusion multiplier (EM) was calibrated for each deposition temperature to control foaming expansion. Material density was determined using extruded cubes with the optimal EM value for each deposition temperature. The influence of deposition temperature on the tensile, compression and flexure characteristics of the foamable filament was studied experimentally.

The foaming expansion ratio, the consistency of the raster width and the raster gap significantly affect the surface roughness of the printed samples. Regardless of the loading conditions, the maximum stiffness and yield strength were achieved at a deposition temperature of 200°C when the PLA specimens had no foam. When the maximum foaming occurred (220°C deposition temperature), the stiffness and yield strength of the PLA specimens were significantly reduced.

The obvious benefit of using foamed materials is that they are lighter and consume less material than bulky polymers. Injection or compression moulding is the most commonly used method for creating foamed products. However, these technologies require tooling to fabricate complicated parts, which may be costly and time-consuming. Conversely, the MEX process can produce extremely complex parts with less tooling expense, reduction in energy use and optimised material consumption.

This study investigates the possibility of stiff, lightweight structures with low fractions of interconnected porosity using foamable filament.

In the event of a crash involving a car, its seats, together with their backrests and head supports, ensure the safety of the passengers. The filling material used for such a car seat is normally made of polyurethane foam. To simulate the behaviour of the seat assembly during a crash, the material characteristics of the seat-filling foam should be appropriately modelled. The purpose of this paper is to present a method, with which the proper parameter values of the selected material model for the seat-filling foam can be easily determined.

In the study, an experiment with the specimen from seat-filling foam was carried out. The results from this experiment were the basis for the determination of the parameter values of the low-density-foam material model, which is often used in crash-test simulations. Two different numerical optimisation algorithms – a genetic algorithm and a gradient-descent algorithm – were coupled with LS-DYNA explicit simulations to identify the material parameters.

The paper provides comparison of two optimisation algorithms and discusses the engineering applicability of the results.

This paper presents an approach for the identification of the missing parameter values of the highly non-linear material model, if these cannot be easily determined directly from experimental data.

The purpose of this paper is to investigate the preparation and the flexural property of hollow glass microspheres (HGMs) filled resin-matrix composites, which have been widely applied in deep-sea fields.

The composites with different contents of HGMs from 47 to 57 Wt.% were studied. The voids in syntactic foams and their flexural properties were investigated.

The results showed that the voids quantity increased because of the increment of HGM content, whereas the exural strength and the exural modulus decreased. The fracture mechanism of the composites was also investigated by scanning electron microscope, which indicated that the composites failed by the crack extending through the microspheres.

The advantages of HGMs with similar hollow spheres will be further investigated in a future research.

Results demonstrated that the properties of the composite might be tailored for specific application conditions by changing the HGM volume fraction.

The HGM filled resin-matrix composite materials have their unique properties and significant application potential. In this work, the resin-HGM composites were synthesized by mechanically mixing defined quantities of HGMs into epoxy resin, by which a kind of syntactic foams with good flexural properties could be obtained.

In the electrostatic spray technique, the atomised paint particles receive a high voltage in the “gun”. Subsequently, the paint particles are attracted to the earthed workpiece, resulting in highly efficient paint utilisation with good coverage of any awkward area (Figure 1).

In conditions where a product is subjected to extreme mechanical loading in a very short time, a strain rate has a significant influence on the behaviour of the product’s material. To accurately simulate the behaviour of the material during these loading conditions, the strain rate parameters of the selected material model should be appropriately used. This paper aims to present a fast method with which the proper strain-rate-dependent parameter values of the selected material model can be easily determined.

In the paper, an experiment was designed to study the behaviour of thin, flat, metal sheets during an impact. The results from this experiment were the basis for the determination of the strain-rate-dependent parameter values of the Cowper–Symonds material model. Optimisation processes with different numbers of required parameters of the selected material model were performed. The optimisation process consists of the method for design of experiment, modelling a response surface and a genetic algorithm.

The paper provides comparison of two optimisation processes with different methods for design of experiment. The performances of the presented method are compared and the engineering applicability of the results is discussed.

This paper presents a new fast approach for the identification of the parameter values of the Cowper–Symonds material model, if these cannot be easily determined directly from experimental data.

Metal foams are a structural and functional composite materials that have received wide attention due to their specific structures and properties. The aim of this study is to investigate the mechanical properties of syntactic foam by using expanded silica gel with the spacer technique.

In this research paper, the vacuum casting production method was used to produce metal syntactic foams including AlSi12 and AlSi8Cu3 matrix and expanded silica gel fillers with diameters of 2–4.75 mm and 4.75–5.6 mm.

As a result of the study, it was observed that as the foam densities increased, the compressive strength values of the samples increased due to the increasing volume fraction of the metallic matrix. Samples with the AlSi12 matrix showed higher compressive strength than samples with the AlSi8Cu3 matrix.

The originality of the study is the comparison of two different main matrix alloys (AlSi12 and AlSi8Cu3) and different pores using expanded silica gel.

The primary objective of this study is to produce one-way slabs made of LWFC with low density and sufficient compressive strength suitable for structural purpose then investigate their flexural behavior under various types of reinforcement and thickness of the slab and the influence of addition of PP fibers reinforcement on the mechanical behavior of reinforced concrete slabs. The specimens were tested using four-point loading. The results concerning load capacity, deflection and failure mode and crack pattern for each specimen were obtained. Also, an analytical investigation of PP fiber and GFG contribution on the flexural behavior of foamed concrete slabs is studied to investigate the significant role of PP fiber on the stress distribution in reinforced foam concrete and predict the flexural moment capacity.

The materials used in this study are cement, fine aggregate (sand), water, PP fibers, foaming agent, chemical additives if required, steel reinforcing rebars and glass fiber grid. The combination of these constituent materials will be used to produce foamed concrete in this research Then this study will present the experimental program of one-way foamed concrete slabs including slabs reinforced with GFR grids and another with steel reinforcements. The slabs will be tested in the laboratory under static loading conditions to investigate their ultimate capacities. The flexural behavior is to the interest of the slabs reinforced with GFR grids reinforcements in comparison with that of one with steel reinforcing rebars. Three groups are considered. (1) Group I: two slabs of PP fiber foamed concrete with minimum required reinforcements. (2) Group II: two slabs of PP fiber foamed concrete with glass fiber grids. (3) Group III: two slabs of PP fiber foamed concrete with the minimum required reinforcements and glass fiber grids.

The experimental results proved the effectiveness and efficiency of this the new system in producing a low density of concrete below 1900 kg/m³ had a corresponding strength of about 17 MPa at least. Besides, the presence of PP fibers had a noticeable improvement on the flexural strength values for all the examined slabs. It was found that the specimens reinforced with steel reinforcement mesh carried higher flexural capacity compared to these reinforced with GFG only. The specimens reinforced with GFG exhibited the lowest flexural capacity due to GFG separation from the concrete substrate. Also, an analytical investigation to predict the flexural strength of all tested specimens was carried out. The analytical results were agreed with the experimental results. Therefore, LWFC can be used as a substitute lightweight concrete material for the production of structural concrete applications in the construction industries today.

Foamed concrete is a wide field to discuss. To achieve the objectives of the project, the study is focused on the foamed concrete with the following limitations: (1) because the aim of this research is to produce foamed concrete suitable for structural purposes, it is decided to produce mixes within the density range 1300–1900 kg/m³. (2) Simply-supported slabs are of considered. (3) This study also looks out by using GFR and without it.

The main objectives of this study were producing structural foamed concrete slabs and investigate their flexural response for residential uses.

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.

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.