Closed Cell Aluminium Composite Foam for Crashworthiness Applications

Abstract

Closed cell aluminium foams with various densities have been made through stir casting technique. The crucible temperature and melt temperature have been controlled to control the foaming temperature for controlling foam cell size and foam densities. The foam made has been then characterized for their micro-architectural characteristics as well as deformation responses. The crash of vehicle takes place at very high speed and therefore, the foams have been tested both at quasi-static and dynamic conditions. It is noted that at dynamic conditions the foams exhibit much higher strength and energy absorption. Then the foams have been filled manually inside the commercially available crash-box and tested using drop weight test methodology. The weight is varied up to 375 kg and speed is varied up to 55 km/h. The deformation behavior of bare foam blocks, foam filled crash box and empty crash boxes have been studied. It is observed that the foam synthesized through this technique is excellent for crash energy absorption. It is also noted that hardly any significant weight will be added into the vehicle. These closed cell foam has also the potential to be used in other transport sectors.