Numerical Simulation and Analysis of the Acoustic Properties of Bimodal and Modulated Macroporous Structures

In recent decades, cellular metallic materials have increasingly been used for control of reverberation and cutback. These materials offer a unique combination of expanded pores, high specific surfaces, improved structural performance, low weight, corrosion resistance at high temperatures, and a fixed/rigid pore network (i.e., at the boundaries, porosity does not change). This study examines the ability of sphere-packing models combined with numerical modelling and simulations to predict the acoustic properties of bimodal and modulated bottleneck-shaped macroporous structures that can realistically be achieved through liquid melts infiltration casting technique. The simulations show that porosity, openings, pore sizes and permeability of the material have significant effects on acoustics, and the predictions are consistent with experimental data substantiated in the literature. The modelling suggests that the creation of bimodal structures increases the capacity of the interstitial pores and pore contacts. The result is improved sound absorption properties and spectra, characterised by a pore volume fraction of 0.73 and a mean pore size to mean pore opening ratio of 4.8 for the 50% volume bimodal structure created at a 10 µm capillary radius. The importance of how pore structure-related parameters and existing fluid flow regimes can modulate the sound absorption performance of macroporous structures was revealed by numerical simulations of the sound absorption spectra for dual-porosity and dilated macroporous structures working from high-resolution tomography datasets. Sound absorption properties were optimised for structures having pore volume fractions between 0.68 and 0.76, maintaining the mean pore size to mean pore opening ratios between 4.0 and 6.0. Using this approach, enhanced and self-supporting macroporous structures may be designed and fabricated for efficient sound absorption in specific applications.