scholarly journals Novel cellular materials for energy absorption applications

2020 ◽  
Author(s):  
Mohammed Mudassir ◽  
Mahmoud Mansour
Keyword(s):  
Additive Manufacturing ◽  
Energy Absorption ◽  
Metal Foams ◽  
Cellular Materials ◽  
Cellular Structures ◽  
Senior Project ◽  
Key Factor ◽  
Good Energy ◽  
To Come ◽  
Energy Absorbing

Cellular materials such as metal foams are porous, lightweight structures that exhibit good energy absorption properties. They have been used for many years in various applications including energy absorption. Traditional cellular structures do not have consistent pore sizes and their behaviors and properties such as failure mechanisms and energy absorption are not always same even within the same batch. This is a major obstacle for their applications in critical areas where consistency is required. With the popularity of additive manufacturing, new interest has garnered around fabricating metal foams using this technology. It is necessary to study the possibility of designing cellular structures with additive manufacturing and their energy absorbing behavior before any sort of commercialization for critical applications is contemplated. The primary hypothesis of this senior project is to prove that energy absorbing cellular materials can be designed. Designing in this context is much like how a car can be designed to carry a certain number of passengers. To prove this hypothesis, the paper shows that the geometry is a key factor that affects energy absorption and that is possible to design the geometry in order to obtain certain behaviors and properties as desired. Much like designing a car, it requires technical expertise, ingenuity, experience and learning curve for designing cellular structures. It is simple to come with a design, but not so much when the design in constrained by stringent requirements for energy absorption and failure behaviors. The scope was limited to the study of metal foams such as the ones made from aluminum and titanium. The primary interest has been academic rather than finding ways to commercialize it. The study has been carried out using simulation and experimental verification has been suggested for future work. Nevertheless, the numerical or simulation results show that energy absorbing cellular structures can be designed that exhibit good energy absorption comparable to traditional metal foams but perhaps with better consistency and failure behaviors. The specific energy absorption was found to be 18 kJ/kg for aluminum metal foams and 23 kJ/kg for titanium metal foams. The average crushing force has been observed to be around 70 kN for aluminum and around 190 kN for titanium. These values are within the acceptable range for most traditional metal foams under similar conditions as simulated in this paper.

scholarly journals Novel Cellular Materials for Energy Absorption Applications

2020 ◽  
Author(s):  
Mohammed Mudassir ◽  
Mahmoud Mansour
Keyword(s):  
Additive Manufacturing ◽  
Energy Absorption ◽  
Metal Foams ◽  
Cellular Materials ◽  
Cellular Structures ◽  
Senior Project ◽  
Key Factor ◽  
Good Energy ◽  
To Come ◽  
Energy Absorbing

Cellular materials such as metal foams are porous, lightweight structures that exhibit good energy absorption properties. They have been used for many years in various applications including energy absorption. Traditional cellular structures do not have consistent pore sizes and their behaviors and properties such as failure mechanisms and energy absorption are not always same even within the same batch. This is a major obstacle for their applications in critical areas where consistency is required. With the popularity of additive manufacturing, new interest has garnered around fabricating metal foams using this technology. It is necessary to study the possibility of designing cellular structures with additive manufacturing and their energy absorbing behavior before any sort of commercialization for critical applications is contemplated. The primary hypothesis of this senior project is to prove that energy absorbing cellular materials can be designed. Designing in this context is much like how a car can be designed to carry a certain number of passengers. To prove this hypothesis, the paper shows that the geometry is a key factor that affects energy absorption and that is possible to design the geometry in order to obtain certain behaviors and properties as desired. Much like designing a car, it requires technical expertise, ingenuity, experience and learning curve for designing cellular structures. It is simple to come with a design, but not so much when the design in constrained by stringent requirements for energy absorption and failure behaviors. The scope was limited to the study of metal foams such as the ones made from aluminum and titanium. The primary interest has been academic rather than finding ways to commercialize it. The study has been carried out using simulation and experimental verification has been suggested for future work. Nevertheless, the numerical or simulation results show that energy absorbing cellular structures can be designed that exhibit good energy absorption comparable to traditional metal foams but perhaps with better consistency and failure behaviors. The specific energy absorption was found to be 18 kJ/kg for aluminum metal foams and 23 kJ/kg for titanium metal foams. The average crushing force has been observed to be around 70 kN for aluminum and around 190 kN for titanium. These values are within the acceptable range for most traditional metal foams under similar conditions as simulated in this paper.

scholarly journals Crashworthiness Optimization of Thin-Walled Rail with Different Collision Boundary Conditions

2015 ◽  
Vol 9 (1) ◽  
pp. 558-563 ◽  
Author(s):  
Hequan Wu ◽  
Libo Cao ◽  
Hongfeng Mao
Keyword(s):  
Boundary Conditions ◽  
Energy Absorption ◽  
Optimal Solution ◽  
Approximate Model ◽  
Impact Angle ◽  
Nsga Ii ◽  
Element Analysis ◽  
Good Energy ◽  
Thin Walled ◽  
Energy Absorbing

As the world automotive crash safety regulations are different, it’s very important to design the energy absorbing structures that satisfy different collision boundary conditions. A large number of vehicle energy absorption beams dimensions were measured and then a common thin-walled rail was chosen. Considering the complexity of automobile collision boundary, finite element analysis and experimental design, interval uncertain algorithms, Kriging approximate model, NSGA - II genetic algorithm were combined to optimize the structure of the thin-walled rail with different impact velocity and different impact angle. Then the Pareto optimal solution was obtained. Thin walled beam after optimization has good energy absorption characteristics under different collision boundary conditions. Research results provide a method for the designing of a car that meets various crash regulations at the same time.

Applications of Cellular Materials – An Overview

2015 ◽  
Vol 766-767 ◽  
pp. 511-517 ◽  
Author(s):  
S. Prabhu ◽  
V.K. Bupesh Raja ◽  
Rajan Nikhil
Keyword(s):  
Energy Absorption ◽  
Weight Reduction ◽  
Weight Ratio ◽  
Cellular Materials ◽  
New Materials ◽  
Low Weight ◽  
New Material ◽  
Good Energy ◽  
Application Specific ◽  
Real Challenge

The research in material science had led to the discovery of new materials; but the real challenge lies in finding suitable application for those materials to be used in various engineering fields. Finding application for a new material is very difficult. Cellular materials have the most promising applications and proved to be satisfactory for its applicability due to their high stiffness-to-weight ratio, better crash energy absorption, fire resistance, non-toxicity, low thermal conductivity, magnetic permeability and lower density. Along with drastic weight reduction and material savings in the case of cellular structures, there are other application-specific benefits like noise and energy absorption, mechanical damping and filtration effects. Various materials exist where weight reduction is the only parameter to be considered but if low weight combined with good energy absorption characteristics or heat resistance is required, then metal foams could be preferred. Possible applications are seen in areas like light weight construction, crash energy absorption, noise control, transport industry, building industry, heat exchangers, purifiers, decoration and arts, etc,. The use of foams can satisfy the demand for light-weighing parts of several branches of industry.

A Three-Dimensional Nested Reinforcing Mesh in Elastomers for Crashworthy Applications

2018 ◽  
Author(s):  
David J. Traina ◽  
Thomas C. Ekstrom ◽  
Owen F. Van Valkenburgh ◽  
Jean-Paul R. Wallis ◽  
David S. Schulman ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Composite Materials ◽  
Energy Absorption ◽  
Peak Load ◽  
Three Dimensional ◽  
Absorption Capacity ◽  
Low Velocity Impact ◽  
Low Velocity ◽  
Mesh Structure ◽  
Energy Absorbing

The advent of additive manufacturing allows for the design of complex 3D geometries that would otherwise be difficult to manufacture using traditional processes. Stereolithographic printing of geometrically reinforced structures gives promise for tunable energy-absorbing composite materials for impact applications. These materials may be suitable for applications in personal sport protection equipment such as knee-pads or helmets. The flexible nature of additive manufacturing can be easily scaled and modified to serve a variety of impact loading applications. In the present study, a three-dimensional nested array of ridged polymeric mesh with tiered high-temperature UV-cured polymer were embedded in a polyurethane matrix to form a new class of functional composite materials designed for multi-use low velocity impact events, and a single-use high velocity or high force impact event. The reinforcements were designed to absorb impact energy by the sequential bending, bucking, and failure of the layers of nested reinforcing members. The energy absorption capacity is further enhanced by the connective elastomer matrix which serves to retain the fractured mesh structure after initial breakage. The peak load is maintained at a relatively modest level while maximizing absorbed energy. Quasi-static loading tests were conducted to measure the peak load, total energy absorbing capability of the material. The energy absorption capability is measured using force-displacement plots and multiple interactions of material combination of reinforcement ring arrays. Tests with and without elastomer matrix, were conducted to understand peak load minimization and energy absorption character of the material.

Bioinspired energy absorbing material designs using additive manufacturing

2021 ◽  
Vol 119 ◽  
pp. 104518
Author(s):  
Aniket Ingrole ◽  
Trevor G. Aguirre ◽  
Luca Fuller ◽  
Seth W. Donahue
Keyword(s):  
Additive Manufacturing ◽  
Absorbing Material ◽  
Energy Absorbing

Lessons from Nature for the Construction of Ceramic Cellular Materials for Superior Energy Absorption

2011 ◽  
Vol 13 (11) ◽  
pp. 1042-1049 ◽  
Author(s):  
Volker Presser ◽  
Stefanie Schultheiß ◽  
Christian Kohler ◽  
Christoph Berthold ◽  
Klaus G. Nickel ◽  
...  
Keyword(s):  
Energy Absorption ◽  
Cellular Materials

CuZnAl Shape Memory Alloys Foams

2012 ◽  
Vol 78 ◽  
pp. 31-39 ◽  
Author(s):  
Ausonio Tuissi ◽  
Paola Bassani ◽  
Carlo Alberto Biffi
Keyword(s):  
Shape Memory Alloys ◽  
Shape Memory ◽  
Physical And Mechanical Properties ◽  
Metal Foams ◽  
Cellular Structures ◽  
Metallic Materials ◽  
Open Cell ◽  
Liquid Infiltration ◽  
Highly Porous ◽  
Metal Infiltration

Foams and other highly porous metallic materials with cellular structures are known to have many interesting combinations of physical and mechanical properties. That makes these systems very attractive for both structural and functional applications. Cellular metals can be produced by several methods including liquid infiltration of leachable space holders. In this contribution, results on metal foams of Cu based shape memory alloys (SMAs) processed by molten metal infiltration of SiO2 particles are presented. By using this route, highly homogeneous CuZnAl SMA foams with a spherical open-cell morphologies have been manufactured and tested. Morphological, thermo-mechanical and cycling results are reported.

An experimental investigation on mechanical performances of 3D printed lightweight ABS pipes with different cellular wall thickness

2021 ◽  
Vol 15 (2) ◽  
pp. 8169-8177
Author(s):  
Berkay Ergene ◽  
İsmet ŞEKEROĞLU ◽  
Çağın Bolat ◽  
Bekir Yalçın
Keyword(s):  
Compressive Strength ◽  
Energy Absorption ◽  
Wall Thickness ◽  
Lattice Structure ◽  
Honeycomb Structure ◽  
Cellular Structures ◽  
Compression Tests ◽  
Absorbed Energy ◽  
Great Opportunity ◽  
3D Printed

In recent years, cellular structures have attracted great deal of attention of many researchers due to their unique properties like exhibiting high strength at low density and great energy absorption. Also, the applications of cellular structures (or lattice structures) such as wing airfoil, tire, fiber and implant, are mainly used in aerospace, automotive, textile and biomedical industries respectively. In this investigation, the idea of using cellular structures in pipes made of acrylonitrile butadiene styrene (ABS) material was focused on and four different pipe types were designed as honeycomb structure model, straight rib pattern model, hybrid version of the first two models and fully solid model. Subsequently, these models were 3D printed by using FDM method and these lightweight pipes were subjected to compression tests in order to obtain stress-strain curves of these structures. Mechanical properties of lightweight pipes like elasticity modulus, specific modulus, compressive strength, specific compressive strength, absorbed energy and specific absorbed energy were calculated and compared to each other. Moreover, deformation modes were recorded during all compression tests and reported as well. The results showed that pipe models including lattice wall thickness could be preferred for the applications which don’t require too high compressive strength and their specific energy absorption values were notably capable to compete with fully solid pipe structures. In particular, rib shape lattice structure had the highest elongation while the fully solid one possessed worst ductility. Lastly, it is pointed out that 3D printing method provides a great opportunity to have a foresight about production of uncommon parts by prototyping.

Design for Additive Manufacturing of Cellular Compliant Mechanism Using Thermal History Feedback

2018 ◽  
Author(s):  
Jivtesh Khurana ◽  
Bradley Hanks ◽  
Mary Frecker
Keyword(s):  
Additive Manufacturing ◽  
Energy Absorption ◽  
Thermal History ◽  
Test Problem ◽  
Compliant Mechanisms ◽  
Compliant Mechanism ◽  
Absorption Capacity ◽  
Unit Cell ◽  
Design For Additive Manufacturing ◽  
Area Of Interest

With growing interest in metal additive manufacturing, one area of interest for design for additive manufacturing is the ability to understand how part geometry combined with the manufacturing process will affect part performance. In addition, many researchers are pursuing design for additive manufacturing with the goal of generating designs for stiff and lightweight applications as opposed to tailored compliance. A compliant mechanism has unique advantages over traditional mechanisms but previously, complex 3D compliant mechanisms have been limited by manufacturability. Recent advances in additive manufacturing enable fabrication of more complex and 3D metal compliant mechanisms, an area of research that is relatively unexplored. In this paper, a design for additive manufacturing workflow is proposed that incorporates feedback to a designer on both the structural performance and manufacturability. Specifically, a cellular contact-aided compliant mechanism for energy absorption is used as a test problem. Insights gained from finite element simulations of the energy absorbed as well as the thermal history from an AM build simulation are used to further refine the design. Using the proposed workflow, several trends on the performance and manufacturability of the test problem are determined and used to redesign the compliant unit cell. When compared to a preliminary unit cell design, a redesigned unit cell showed decreased energy absorption capacity of only 7.8% while decreasing thermal distortion by 20%. The workflow presented provides a systematic approach to inform a designer about methods to redesign an AM part.

scholarly journals Energy Absorption Characteristics of Foam Filled Tri Circular Tube under Bending Loads

2021 ◽  
Vol 15 ◽  
pp. 159-164
Author(s):  
Fauzan Djamaluddin
Keyword(s):  
Energy Absorption ◽  
Failure Modes ◽  
Circular Tube ◽  
Comparative Investigation ◽  
Tubular Structures ◽  
Vehicle Engineering ◽  
Bending Resistance ◽  
Bending Loads ◽  
Foam Filled ◽  
Energy Absorbing

In this study, the researcher carried out a comparative investigation of the crashworthy features of different tubular structures with a quasi-static three bending point, like the foam-filled two and tri circular tube structures. Energy absorption capacities and failure modes of different structures are also studied. Furthermore, the general characteristics are investigated and compared for instance the energy absorption, specific energy absorption and energy-absorbing effectiveness for determining the potential structural components that can be used in the field of vehicle engineering. Experimental results indicated that under the bending conditions, the tri foam-filled structures were higher crashworthiness behaviour than the two foam-filled circular structures. Therefore, this study recommended the use of crashworthy structures, such as foam-filled tri circular tubes due to the increased bending resistance and energy-absorbing effectiveness.

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