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Dynamic bending behaviour of magnesium alloy rectangular thin-walled beams filled with polyurethane foam

Zhou, Ping and Beeh, Elmar and Kriescher, Michael and Friedrich, Horst E. and Kopp, Gundolf (2016) Dynamic bending behaviour of magnesium alloy rectangular thin-walled beams filled with polyurethane foam. International Journal of Crashworthiness. Taylor & Francis. DOI: 10.1080/13588265.2016.1208715 ISSN 1358-8265

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Official URL: http://dx.doi.org/10.1080/13588265.2016.1208715

Abstract

This study investigates the load-deflection curve characteristics and deformation/fracture modes and energy absorption capacity for polyurethane foam-filled magnesium alloy AZ31B rectangular thin-walled beams under dynamic three-point bending loads, and compares these characteristics with those for mild steel DC04 beams. Different foam-filled AZ31B beams with a variation of foam density (0.05 g/cm3, 0.20 g/cm3 and 0.30 g/cm3) were fabricated through several manufacturing processes: cold bending, tungsten inert gas welding, cathodic dip painting and polyurethane foam injection. It was found that 0.20 g/cm3 and 0.30 g/cm3 foams stabilised the cross sections of the thin-walled AZ31B beams and no inward folds occurred during the bending process, which resulted in significantly higher load carrying capacity than the empty beam. A nonlinear non-monotonic relationship between the specific energy absorption and the foam density was found for the foam-filled AZ31B beams. The AZ31B beam filled with 0.20 g/cm3 foam reached the highest specific energy absorption; moreover, it absorbed nearly 33% more energy and reached nearly 2.9 times higher specific energy absorption than the foam-filled DC04 beam filled with the same foam, although the former one was nearly 54% lighter. This outperformance is associated to the high work hardening rate of AZ31B in compression, where more material is involved in plastic deformation. However, the foam-filled AZ31B beams tend to fracture at the compression and tension walls, because the foam exhibits brittle fracture behaviour in tension and AZ31B exhibits low ductility in compression and plane-strain conditions, which limits their energy absorption at a larger deflection.

Item URL in elib:https://elib.dlr.de/105674/
Document Type:Article
Title:Dynamic bending behaviour of magnesium alloy rectangular thin-walled beams filled with polyurethane foam
Authors:
AuthorsInstitution or Email of AuthorsAuthors ORCID iD
Zhou, Pingping.zhou (at) dlr.deUNSPECIFIED
Beeh, Elmarelmar.beeh (at) dlr.deUNSPECIFIED
Kriescher, Michaelmichael.kriescher (at) dlr.deUNSPECIFIED
Friedrich, Horst E.horst.friedrich (at) dlr.deUNSPECIFIED
Kopp, Gundolfgundolf.kopp (at) dlr.deUNSPECIFIED
Date:July 2016
Journal or Publication Title:International Journal of Crashworthiness
Refereed publication:Yes
Open Access:No
Gold Open Access:No
In SCOPUS:Yes
In ISI Web of Science:Yes
DOI :10.1080/13588265.2016.1208715
Publisher:Taylor & Francis
Series Name:International Journal of Crashworthiness
ISSN:1358-8265
Status:Published
Keywords:Magnesium alloy; Polyurethane foam; Thin-walled structure; Energy absorption; fracture behaviour
HGF - Research field:Aeronautics, Space and Transport
HGF - Program:Transport
HGF - Program Themes:Terrestrial Vehicles (old)
DLR - Research area:Transport
DLR - Program:V BF - Bodengebundene Fahrzeuge
DLR - Research theme (Project):V - NGC Fahrzeugstruktur (old)
Location: Stuttgart
Institutes and Institutions:Institute of Vehicle Concepts > Lightweight and Hybrid Design Methods
Deposited By: Beeh, Elmar
Deposited On:12 Oct 2016 11:45
Last Modified:06 Sep 2019 15:18

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