Microstructure-based modeling to characterize low pore density open-cell foams and its experimental validation

Microlattices with large pore sizes are involved in many multifunctional applications, so it is essential to understand their acoustic properties. However, for these low pore density microlattice foams, the classical homogenization or "equivalent fluid" methods fail abruptly. This paper proposes and discusses a microstructure-based direct fluid model (DFM) that would help to predict the acoustic performance of low pore density periodic open-cell foams with spherical pores. The DFM is simulated directly, including the microscale geometric features inherent in the unit cell. A comparative study is performed for designed three-dimensional (3D) body-centered-cubic (BCC) porous foams having pores per inch (PPI) ranging from 1 to 12 over the frequency range of 500-4100 Hz with equivalent fluid models and experiments. The study shows the extent of deviation in homogenization-based methods from the experiment for PPI < 5. On the other hand, the acoustic performance parameters predicted with the DFM agree well with experiments on 3D-printed samples fabricated by additive manufacturing of varying PPI starting from 1. This study shows that the DFM is a valid method to predict the acoustics of low PPI microlattices. Furthermore, the gradual transition from dissipative to the reactive regime with a decrease in PPI is also brought out.