Potential applications of foam-filled sections are for the automotive structures. A foam-filled section can be used for the front rail and firewall structures to absorb impact energy during frontal or side collision. In the case of biaxial loading where bending and axial compression are involved in the crushing mechanics, the foam filler will be significant in maintaining progressive crushing of the thin-walled structures so that more impact energy can be absorbed. In the case of side collision, the foam-filled section can be used to strengthen the B-pillar structure to avoid severe intrusion in the passenger compartment. Furthermore, the foam-filled section can also be used in the A-pillar and roof frame structures to prevent severe roof crush during roll over accident. The experiments and numerical simulations of foam-filled beams have shown significant increase in the bending resistance. The most important results are summerized as follows: The presence of the foam filler changes the crushing mode of the thin-walled beam from one localized fold to multiple propagating folds. This modified mechanism prevents the drop in load carrying capacity due to the formation of more plastic hinge lines, producing a limited sectional crush. Therefore more bending energy can be dissipated. Partial foam filling offers significant reduction of the foam weight maintaining higher crushing resistance. The effective foam length Lf,eff should be used as a guidline for designing the partially foam-filled beam. Both numerical and experimental results show a good agreement in using the effective foam length as the minimum insert length to obtain optimum bending resistance to weight efficiency.


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    Experimental study of crush behavior of sheet aluminium foam-filled sections

    Chen,W. / Nardini,D. / Massachusetts Inst.of Technology,Cambridge,US et al. | Kraftfahrwesen | 2000


    Biaxial bending collapse of thin-walled beams filled partially or fully with aluminium foam

    Kim,H.S. / Wierzbicki,T. / Massachusetts Inst.of Technology,Cambridge,US | Kraftfahrwesen | 2000


    Automotive roof crush, structural foam enhancement solution

    Pathare,R. / Mansour,M. / Delphi Automotive,US | Kraftfahrwesen | 2009


    Automotive Roof Crush, Structural Foam Enhancement Solution

    Mansour, Mirdamadi / Pathare, Rahul | SAE Technical Papers | 2009