Compressive properties and energy absorption of metal-polymer hybrid cellular structures

Abstract

This study presents experimental results on the mechanical behavior of aluminum alloy cellular structures filled with Polypropylene or ABS. Two types of base cell geometries were analyzed, having uniform cell structure and with a dual-size cell arrangement seeking optimized mechanical properties. The structures were manufactured by lost-wax casting using 3D printed components for internal structure definition. The polymer fill was introduced through a process of temperature assisted impregnation in a specially developed tool. Results for stiffness and energy absorption were obtained and compared on weight efficiency basis. The results are indicative of higher efficiency of the dual-size structures having PP/ABS filling that may be considered for energy absorption parts in compressive loading.