Stochastic mechanical modeling of Duocel foam from micro-to macro-length scales

Duocel aluminum foam is a critical component of state-of-the-art micrometeoroid and orbital debris shielding. However, its randomly-oriented constituent ligaments create a significant variability in properties at different length scales. An understanding of the transition from micro-(local) to macro-(bulk) length scales are critical to quantifying the effects of various inhomogenitiees like inclusions, cracks, etc. Rather than homogenizing the material such that its unique characteristic structural features are neglected, we present a stochastic modeling approach that integrates complex structure and predicts elastic mechanical behavior. The approach includes a computational toolkit for generating physically-motivated model representative volume elements (mRVEs) of Duocel, as well as a methodology for computing the probability density functions of elastic properties for sets of mRVEs. We also demonstrate the validity of the approach by comparing computationally predicted results with experimental measurements provided by Duocel’s manufacturer, ERG Aerospace.