About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Aluminum Alloys: Development and Fabrication Symposium and Supplier Forum
|
| Presentation Title |
Hybrid Experimental-Numerical Crashworthiness Assessment of Aluminium Foam-Filled Extrusions |
| Author(s) |
Divyansh Singh Sisodia, Gautam Wagle, Shreyas Khot |
| On-Site Speaker (Planned) |
Divyansh Singh Sisodia |
| Abstract Scope |
Aluminium foam-filled extrusions provide a potential route to enhance the crashworthiness of lightweight automotive structures through the interaction of thin-wall folding and cellular-core compaction. The crashworthiness of these structures is investigated through a hybrid experimental-numerical approach. The stress-state-dependent failure behaviour of the extrusion alloy is characterized using tensile testing, digital image correlation, and finite element analyses. Compression tests on the aluminium foam are used to characterize its collapse, plateau, and densification behaviour and calibrate an established pressure-sensitive constitutive formulation for volumetric compaction. Hollow and foam-filled extrusions are tested and simulated to evaluate force-displacement response, foam compaction, wall-fracture initiation, and energy absorption. The developed simulation framework provides a structured approach for quantifying foam and extrusion interaction and supports material and geometry co-optimization of lightweight crash structures. The methodology also establishes a pathway for incorporating foam-filled concepts into automotive extrusion design workflows while reducing dependence on repeated crush tests. |
| Proceedings Inclusion? |
Planned: Light Metals |
| Keywords |
Modeling and Simulation, Aluminum, |