Quasi Static Compressive Behavior of Al-Si-SiC-xFe Foam Filled Crash Boxes

Document Type : Original Articles

Authors

• Mohammad Javad Nayyeri
• Mohammad Javad Khaje Ali
• Seyyed Mohammad Hossein Mirbagheri

Amirkabir University of Technology

10.22067/ma.v27i2.25765

Abstract

The effect of iron on the structure and absorbed energy in thin-walled brass tubes filled with Al-Si-SiC-xFe foams, produced through powder metallurgy rout, during uniaxial compressive loading was evaluated. Results showed that by increasing the iron content up to 3 wt.% will increase the sphericity of the cells, foam density and homogeneity of the structure. However, the formation of Al4Fe2Si intermetallic and micro-shrinkage in the cell walls and edges resulted in a decrease in the magnitude of the absorbed energy. Moreover, according to experimental data, a model was developed based on the relative density of the foam along with the geometry of the foam and tube. This model was used to predict the energy absorption of foam filled tubes.

Keywords

• Closed Cell Aluminum Foam
• Powder Metallurgy
• Thin Walled Structure
• Energy Absorption

---

References

1. Abramowicz W., "Thin-walled structures as impact energy absorbers", Thin-Walled Structures, vol. 41, Issue 2–3, pp. 91-107 (2003).

2. Langseth M., Hopperstad O.S., Berstad T., "Crashworthiness of aluminium extrusions: validation of numerical simulation, effect of mass ratio and impact velocity", International Journal of Impact Engineering, vol. 22, Issue 9–10, pp. 829-854 (1999).

3. Reyes A., Langseth M., Hopperstad O.S., "Square aluminum tubes subjected to oblique loading", International Journal of Impact Engineering, vol. 28, Issue 10, pp. 1077-1106 (2003).

4. Tang Z., Liu S., Zhang Z., "Energy absorption properties of non-convex multi-corner thin-walled columns", Thin-Walled Structures, vol. 51, Issue 1, pp. 112-120 (2012).

5. Yamashita M., Kenmotsu H., Hattori T., "Dynamic axial compression of aluminum hollow tubes with hat cross-section and buckling initiator using inertia force during impact", Thin-Walled Structures, vol. 50, Issue 1, pp. 37-44 (2012).

6. Jones N., "Structural Impact", Cambridge University Press (1989).

7. Cheng Q. et al., "Energy absorption of aluminum foam filled braided stainless steel tubes under quasi-static tensile loading conditions", International Journal of Mechanical Sciences, vol. 48, Issue 11, pp. 1223-1233 (2006).

8. Ashby M.F. et al., "Metal Foams, A design guide", Butterworth Heinmann (2000).

9. Najafi A., Rais-Rohani M., "Mechanics of axial plastic collapse in multi-cell, multi-corner crush tubes", Thin-Walled Structures, vol. 49, Issue 1, pp. 1-12 (2011).

10. Reyes A., Hopperstad O.S., Langseth M., "Aluminum foam-filled extrusions subjected to oblique loading: experimental and numerical study", International Journal of Solids and Structures, vol. 41, Issue 5–6, pp. 1645-1675 (2004).

11. Zarei H.R., Kröger M., "Bending behavior of empty and foam-filled beams: Structural optimization", International Journal of Impact Engineering, vol. 35, Issue 6, pp. 521-529 (2008).

12. Zarei H.R., Kröger M., "Optimization of the foam-filled aluminum tubes for crush box application", Thin-Walled Structures, vol. 46, Issue 2, pp. 214-221 (2008).

13. Kavi H., Toksoy A.K., Guden M., "Predicting energy absorption in a foam-filled thin-walled aluminum tube based on experimentally determined strengthening coefficient", Materials & Design, vol. 27, Issue 4, pp. 263-269 (2006).

14. Santosa S., Wierzbicki T., "Crash behavior of box columns filled with aluminum honeycomb or foam", Computers & Structures, vol. 68, Issue 4, pp. 343-367 (1998).

15. Santosa S.P. et al., "Experimental and numerical studies of foam flled sections", International Journal of Impact Engineering, vol. 24, pp. 504-534 (2000).

16. Santosa S.P. et al., "Experimental and numerical studies of foam-filled sections", International Journal of Impact Engineering, vol. 24, Issue 5, pp. 509-534 (2000).

17. Seitzberger M. et al., "Experimental studies on the quasi-static axial crushing of steel columns filled with aluminium foam", International Journal of Solids and Structures, vol. 37, Issue 30, pp. 4125-4147 (2000).

18. Zhang C.-j., Feng Y., Zhang X.-b., "Mechanical properties and energy absorption properties of aluminum foam-filled square tubes", Transactions of Nonferrous Metals Society of China, vol. 20, Issue 8, pp. 1380-1386 (2010).

19. Hanssen A.G., Langseth M., Hopperstad O.S., "Static and dynamic crushing of square aluminium extrusions with aluminium foam filler", International Journal of Impact Engineering, vol. 24, pp. 347-383 (2000).

20. Britan A. et al., "The effect of fine particles on the drainage and coarsening of foam", Colloids and Surfaces A: Physicochemical and Engineering Aspects, vol. 344, Issue 1–3, pp. 15-23 (2009).

21. Deqing W., Ziyuan S., "Effect of ceramic particles on cell size and wall thickness of aluminum foam", Materials Science and Engineering: A, vol. 361, Issue 1–2, pp. 45-49 (2003).

22. Kennedy A.R., Asavavisitchai S., "Effects of TiB2 particle addition on the expansion, structure and mechanical properties of PM Al foams", Scripta Materialia, vol. 50, Issue 1, pp. 115-119 (2004).

23. Esmaeelzadeh S., Simchi A., Lehmhus D., "Effect of ceramic particle addition on the foaming behavior, cell structure and mechanical properties of P/M AlSi7 foam", Materials Science and Engineering: A, vol. 424, Issue 1-2, pp. 290-299, (2006).

24. Gergely V., Clyne T.W., "Drainage in standing liquid metal foams: modelling and experimental observations", Acta Materialia, vol. 52, Issue 10, pp. 3047-3058 (2004).

25. Mondolfo L.F., "Aluminum alloys: structure and properties", London: Butterworths (1976).

26. Yi J.Z. et al., "Effect of Fe-content on fatigue crack initiation and propagation in a cast aluminum–silicon alloy (A356–T6)", Materials Science and Engineering: A, vol. 386, pp. 396–407 (2004).

27. Baumgärtner F., Duarte I., Banhart J., "Industrialization of Powder Compact Foaming Process", Advanced Engineering Materials, vol. 2, Issue 4, pp. 168-174 (2000).

28. خواجه‌علی م.ج.، "ساخت قوطی های فومی تو پر و بررسی پارامترهای موثر بر جذب انرژی آنها"، دانشکده مهندسی معدن و متالورژی، دانشگاه صنعتی امیرکبیر (1390).

29. Gupta S.P., "Intermetallic compound formation in Fe–Al–Si ternary system: Part I", Materials Characterization, vol. 49, Issue 4, pp. 269-291 (2002).

30. Maitra T., Gupta S.P., "Intermetallic compound formation in Fe–Al–Si ternary system: Part II", Materials Characterization, vol. 49, Issue 4, pp. 293-311 (2002).

31. Mukherjee M., et al., "The effect of cooling rate on the structure and properties of closed-cell aluminium foams", Acta Materialia, vol. 58, Issue 15, pp. 5031-5042 (2010).

32. Alavi Nia A., Haddad Hamedani J., "Comparative analysis of energy absorption and deformations of thin walled tubes with various section geometries", Thin-Walled Structures, vol. 48, Issue 12, pp. 946-954 (2010).

33. Raj R.E., Daniel B.S.S., "Structural and compressive property correlation of closed-cell aluminum foam", Journal of Alloys and Compounds, vol. 467, Issue 1–2, pp. 550-556 (2009).