Densification Mechanics of Polymeric Syntactic Foams

In this paper, a fundamental understanding of the densification mechanics of polymeric syntactic foams under compressive loading is established. These syntactic foams are closed cell composite foams with thin-walled microballoons dispersed in a matrix (resin) whose closed cell structure provides excellent mechanical properties, like high strength and low density. There are several parameters that can contribute towards their mechanical properties, including, microballoon volume fraction, microballoon wall thickness, bonding between the microballoons and the matrix, and the crushing strength of microballoons. Conducting purely experimental testing by varying these parameters can be very time sensitive and expensive. Also, identification of densification mechanics is challenging using experiments only. Higher densification stress and energy are favorable properties under foam compression or crushing. Hence, the influence of key structural and material parameters associated with syntactic foams that dictate the mechanics of densification is studied here by implementing micromechanics based computational models and multiple linear regression analysis. Specifically, specific densification stresses and energy, which are densification stresses and energy normalized by weight, are evaluated which are more relevant for a wide variety of weight saving applications. Microballoon crushing strength and volume fraction are identified as the parameters that have the higher influence on densification stress and energy, and their specific counterparts, whereas the interfacial bonding has the least impact. In addition, designing aspects of syntactic foams with specified overall density are discussed by mapping microballoon volume fraction and wall thickness.