Mechanical-thermal coupling of carbon fiber/aluminum/silicone foams under axial loading

• Adding CF or Al into a silicone foam can reduce the size of voids inside it. • CF and Al also improve the elastic and thermal behaviors of silicone matrix. • A homogenization scheme for a four-phase system including voids is developed. • Interface effects consider the Kapitza resistance and filler contact resistance. • The axial compression-dependent thermal conductivity is calculated for CF/Al/SFs. Mechanical-thermal coupling mechanisms in silicone foam (SF) composites play a crucial role in optimizing their performance for aerospace, automotive, and construction applications, where lightweight design and thermal efficiency are essential. This study presents a comprehensive theoretical framework to evaluate the mechanical and thermal properties of SF composites reinforced by carbon fibers (CF) and aluminum particles (Al) under axial pressure. A four-phase composite model is developed to incorporate inclusions, matrix and voids, accounting for morphological changes in the foam structure. The model employs the Mori-Tanaka method to predict the elastoplastic behaviors, while effective-medium approximation is used to determine thermal conductivity. The framework also considers interfacial effects, including interfacial sliding, the Kapitza resistance, and filler-filler contact. Comparisons with experimental data validate the model and reveal that CF/Al/SF composites exhibit superior thermal and mechanical properties, with CFs demonstrating a more pronounced impact. These findings underscore the interplay between mechanical loading, void morphology, and thermal performance, highlighting the importance of tailoring CF/Al ratios and processing conditions to achieve synergistic mechanical-thermal properties of SF-based composites.