Elastic behaviour and failure mechanism in epoxy syntactic foams: The effect of glass microballoon volume fractions

A representative elementary volume (REV) in epoxy syntactic foams was generated to incorporate randomly distributed glass microballoons that followed a log-normal size distribution. Finite element modelling of the REV foam was developed and experimentally validated to investigate the elastic behaviour and failure mechanism in the foams with different microballoon volume fractions (V). The localised stresses concentrate in various zones within the foam, and can cause the vertical splitting fracture of microballoons and the micro-crack formation in the matrix. Dependent on the microballoon volume fraction, micro-cracks can propagate to join adjacent micro-cracks and voids left by fractured microballoons, and finally develop into a macro-crack either in the preferred longitudinal (for low V) or diagonal (for high V) directions. This is consistent with the macroscopic observations of the fracture process in the foam specimens. It was also found that elastic characteristics of the foam vary with microballoon volume fractions.