Fracture mechanics of stainless steel foams

The fracture toughness and mode I fatigue crack growth (FCG) tests for open cell stainless steel foam with 45 pores per inch (ppi) have been carried out. In this study, the R-curve of crack propagating from a pre-crack was measured for a compact tension specimen by fracture toughness test. The fracture mechanics response was simulated by using an inverted spherical foam modeling approach. The results attained for crack extension rates were described by delta K, using the Paris-power law approach. The compact tension porous stainless steel specimens have shown full plastic collapse along the ligaments. The microstructure of the foam had a significant influence on the fatigue crack propagation rate. It was found that stainless steel foam has higher Paris exponent than solid stainless steel and the high Paris exponent was explained by crack bridging. The simulation results showed that initiation toughness values strongly depend on failing struts, resulting in cracks that are si gnificantly curved and kinked along their weakest path in stainless steel foam. The results from this study help in predicting and improving mechanical properties of metallic foams with open cell structure.