Sintering graded foamed beads: Compressive properties

Designing the foam structures in terms of density and morphology gives the chance to tune their mechanical and functional properties to the specific application. Nowadays, this design has been leveled up by the introduction of graded foams which are characterized by spatially nonuniform densities and/or morphologies. Graded foams have proved superior compared to uniform one in numerous examples and loading conditions but in pure compressive loading, where properties such as the Young's modulus of graded foams are always inferior to uniform ones. When using sintered beads foams, macroscopic pure compression may induce local bending on the single bead, which can be exploited to induce stiffening. This thesis was investigated on both polystyrene and thermoplastic polyurethane samples made by foamed beads sintered in a cylindrical mold. The response to compressive tests of graded foams made by sintering beads having nonuniform cells structures was compared to the uniform counterparts. The results evidenced that, at same average density, foams had up to a 30% ca. of increase of the Young's modulus when the beads are characterized by a denser outer layer.