An experimental study into uncertainty and scatter in the compressive response of closed cell metallic foams

Objective of the present study is an experimental investigation of the uncertainty effects in the mechanical properties of closed-cell foams caused by their microstructural disorder. Using an aluminum foam manufactured by a powder-metallurgical route, the correlations between microstructure and mechanical properties are analyzed. The microstructure is characterized in terms of density as well as cell size and geometry in dependence on the individual spatial direction and position, respectively. Subsequently, the mechanical properties are determined in compression experiments, also considering spatial position and testing direction. In order to provide a profound statistical data base, a total of 147 experiments is performed. The results are analyzed with respect to the probability distributions of the individual microstructural and mechanical material properties as well as their correlation. • Correlation between microstructure and mechanical properties of Al foam established. • Uncertain local density most important property in uncertain material response. • Uncertain cell shape second most important variable causing material uncertainties. • Uncertainty effects of initial morphology restricted to initial stress–strain curve.