Experimental and two-scale numerical studies of aluminum foam for crash protection components
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Author list: Uthaisangsuk V.; Srimanosaowapak S.; Thant A.
Publisher: Taylor and Francis Group
Publication year: 2025
ISSN: 1539-7734
eISSN: 1539-7742
Languages: English-Great Britain (EN-GB)
Abstract
In this study, mechanical and energy absorption characteristics of aluminum foam were investigated, with a focus on its application for electric vehicle crash safety. Experimental uniaxial compression tests and FE modeling were conducted to examine plastic deformation behaviors of A356.2 aluminum foams produced by an infiltration casting method. Representative volume element (RVE) models based on a random compact sphere structure were generated for describing mesoscale foam features. The RVE models, in which flow stress curve and stress state dependent failure criterion of the bulk aluminum determined from experiments were applied, fairly predicted the compressive deformation of foams with varying porosities. Subsequently, a macroscopic crushable foam model was calibrated with RVE simulation results and further employed to investigate crashworthiness of foam infilled components. Three-point bending tests showed that integrating aluminum foam into beam structures significantly improved energy absorption while minimizing weight, especially when embedding partial foam infill structures. Finally, side pole impact simulations of a frame assembly of battery housing confirmed that foam-filled rocker beams offered superior energy absorption compared to conventional extrusion profile-filled beams. Partially foam-filled designs provided an optimal balance between crashworthiness performance and weight reduction. Hereby, maximum intrusion was also reduced and therefore battery protection in electric vehicles was enhanced. © 2025 Elsevier B.V., All rights reserved.
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