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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


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
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 ISI Web of Science:Yes
DOI :10.1080/13588265.2016.1208715
Publisher:Taylor & Francis
Series Name:International Journal of Crashworthiness
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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