Three-dimensional imaging of large compressive deformations in elastomeric foams

Specimens of silica-reinforced polysiloxane foam pads were three-dimensionally imaged during axial compressive loading to densification. The foams' behavior was highly nonlinear and showed the three characteristic regions of linear elastic, elastic buckling, and densification. A finite-element technique, based upon conversion of the image voxels to finite elements, was used to calculate the mechanical properties of the foams. The results were compared with conventional mechanical testing and theory. The finite-element calculations were in excellent agreement with experimental stress–strain data over the entire range of compressive loading. Theoretical models, on the other hand, overestimated the stiffness of the foam above the elastic buckling stress by not correctly predicting the abruptness of the transition from elastic buckling to densification. Three-dimensional analysis of the deformed microstructures indicated that there was a critical foam density beyond which the cell morphology suddenly changed from open-celled to closed-celled and that this “phase”-like transition was responsible for the abrupt increase in stiffness near densification. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 80: 1746–1755, 2001