Abstract
Terocore, an epoxy-based foam reinforcement, can enhance the crash strength and energy management of 6xxx series T6 temper aluminium extrusion under static and dynamic axial loading. Epoxy-based Terocore requires confinement with an aluminium sheet envelope that wraps around the uncured Terocore for installation. This investigation program consists of CAE analysis and components testing. CAE analysis computes the dynamic mean crash load and equivalent aluminium thickness to Terocore reinforced extruded aluminium components. Component testing consists of static and 30 mph testing of extruded aluminium components, with and without reinforcement. Epoxy-based foam reinforcement with an aluminium backing sheet can increase the crash load and total energy absorption by 50–100% but produces little change in the specific energy absorption of the composite component (aluminium extrusion plus epoxy foam) for the 2 mm wall thickness extrusions tested in this study. Base aluminium extrusion weight increase to produce the equivalent strength and energy enhancement of reinforced extrusion is approximately equal to the weight of the reinforcement. The paper addresses CAE analysis, component testing and design recommendations for epoxy-based foam reinforcement to improve strength and energy management in extruded aluminium rails.
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