Abstract
Thermal-mechanical coupling during the molding process can cause compressive yield in the polymer foam core and then affect the molding quality of the sandwich structure. This work investigates the compressive mechanical properties and failure mechanism of polymethacrylimide (PMI) foam in the molding temperature range of 20-120 °C. First, the DMA result indicates that PMI foam has minimal mechanical loss in the 20~120 °C range and can be regarded as an elastoplastic material, and the TGA curve further proves that the PMI foam is thermally stable within 120 °C. Then, the compression results show that compared with 20 °C, the yield stress and elastic modulus of PMI foam decrease by 22.0% and 17.5% at 80 °C and 35.2% and 31.4% at 120 °C, respectively. Meanwhile, the failure mode changes from brittle fracture to plastic yield at about 80 °C. Moreover, a real representative volume element (rRVE) of PMI foam is established by using Micro-CT and Avizo 3D reconstruction methods, and the simulation results indicate that PMI foam mainly shows brittle fractures at 20 °C, while both brittle fractures and plastic yield occur at 80 °C, and most foam cells undergo plastic yield at 120 °C. Finally, the simulation based on a single-cell RVE reveals that the air pressure inside the foam has an obvious influence of about 6.7% on the yield stress of PMI foam at 80 °C (brittle-plastic transition zone).