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Aluminum foams have recently received special attention due to their peculiar mechanical properties. For example, their energy absorption capacity in crash events and low density are very desirable characteristics for several applications. Actually, the energy absorption of aluminum foams is even magnified when they interact with aluminum tubes or when tubes are filled with aluminum foams. Since the automotive industry constantly demands light materials with high strain energy absorption capacity to reduce fuel consumption and fulfill safety requirements, aluminum foams are an excellent alternative to satisfy such demands. This work shows, by numerical simulations of reduced and full vehicle models, the usefulness of aluminum foams incorporated in a car structure when subjected to “35 mph Frontal Barrier Impact Test”, according to the Federal Motor Vehicle Safety Standard No 208 (FMVSS). Foam was used to dramatically improve load capacity and crush displacement. Thus, dash panel intrusions and acceleration gradient were reduced, increasing the vehicle safety performance. Finally, it is shown that foams can be beneficial in electric vehicle development by increasing load capacity.

Aluminum foam to improve crash safety performance: a numerical simulation approach for the automotive industry