Analysis of the meso‐mechanical deformation behavior of Al foams and Ni/Al hybrid foams using time‐lapse μCT measurements and 3D Optical Flow

Metal foams are an interesting class of bio‐inspired materials for lightweight construction and energy absorption. Commonly, aluminum (Al) foams are used. However, the mechanical properties have been improved by coating pure Al foams with a nanocrystalline nickel (Ni) coating resulting in Ni/Al hybrid foams. Herein, the meso‐mechanical deformation mechanisms in Al foams and the changes in the mechanisms in Ni/Al hybrid foams are studied using time‐lapse micro‐computed tomography measurements in comparison between numerical modeling using voxel finite element models and evaluation of displacement fields using 3D optical flow. This gives never‐seen insights into the highly localized 3D deformation mechanisms within the entire volume of the foams and not only on the surfaces as given by conventional digital image correlation methods. Displacements calculated by the 3D optical flow algorithm demonstrate its possibility to reveal a significant concentration of plastic deformation, particularly evident when deformation occurs within a distinct, slightly inclined band in the central region. Common numerical simulations using standard plasticity models do not accurately capture this localized deformation, underscoring the need to integrate damage and softening models into the simulation.