Design and application of aluminum foams for car body structures

The objective of this research is to investigate on available aluminum foam samples properties by software to determine whether their characteristics are suitable for car crash energy absorbing use. If not good fit with the target, design possible solution in Abaqus together with CES Edupack (a software selection of materials, manufacturing processes, joining and finishing). Three point bending test and compression tests were performed on samples. Applying MATLAB image analysis tool to recognize foam surface porosity and relevant calculation based on the Ashby theory (metal foam constitutive law are considered). Moreover, specimens were modeled for the finite element analysis in Abaqus to compare simulation results against experiments data. Applying the reasonable properties range provided by CES Edupack for foam building in Abaqus, The design phase will represent a reliable evaluation and good prediction for foam energy-absorbing ability during crash condition. some possible improvements are discussed at the end.