One of the most important targets in vehicle design is passive safety; this more and more stringent requirement leads the designer towards new vehicle architectural solutions and innovative materials. Aluminium foams are a new class of materials with promise an improvement of vehicle crashworthiness, combining the properties derived from the cellular structure, in particular the lightness, with the typical behavior of metals. The behavior of a bumper system based on aluminium foam (AlSi7MgCuNi + 15 % SiCp) filled crashboxes (Al 6060-T6) was characterised by static and dynamic compression tests. It was found that existing design formulae applying to aluminium foam based crashboxes resulted in an overall good agreement compared with the experiments. Furthermore, the tests carried out revealed that both the single crashbox and the complete front-end satisfy the design constraints in terms of energy absorption, maximum force transmitted and dimensions.


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