Novel cellular perlite–epoxy foams: Effect of density on mechanical properties

Abstract

A novel type of economical lightweight foam with density from 0.15 to 0.45 g/cm³ was made from a high volume fraction of expanded volcanic glass (perlite) in an epoxy matrix. The compressive strength, effective elastic modulus, and modulus of toughness of the foams all increased with the foam density. The strength increased linearly, peaking at 1.7 MPa whereas the effective elastic modulus and modulus of toughness increased at parabolically increasing and decreasing rates, respectively. The specific compressive stress of the newly developed foam in the density range of 0.3–0.44 g/cm³ is comparable with foams made from alumina, aluminium–silicon carbide, closed cell phenolic resin, and closed cell polypropylene. Post-test SEM observations coupled with photogrammetry during the tests revealed three different failure modes: longitudinal splitting, shear failure, and compression failure were present over the whole density range. The material was found to be a good candidate for the stiffening cores within sandwich panels.