Comparison of mechanical performances of the crash-boxes filled with various percentages of aluminium foam

In this study, firstly, compression tests of aluminium foam material were carried out to determine its constitutive material model. This model was then utilized in virtual crash tests of crash-boxes filled with various percentages of aluminium foam. The results were compared with those of the empty crash-boxes to evaluate their mechanical performances. It was observed that the foam-filled crash-boxes exhibited superior properties of plateau force, impact duration, deformation behaviour and energy absorption, which get better by the increasing foam percentage