Energy Absorption Efficiency Research Articles

Effect of cell diameter variations on the mechanical behavior of aluminum foams: Experiments and modeling

Aluminum foams can be manufactured in a variety of cell sizes; however, existing models focus primarily on density and neglect the effect of cell size. Furthermore, aluminum foams with different cell diameters exhibit diverse mechanical properties. In this study, a quasi-static/dynamic compression test was performed to investigate the mechanical behavior, damage patterns, and damage mechanisms of aluminum foams with different cell diameters. The results demonstrate that the compressive properties of aluminum foams undergo significant changes. As the cell diameter increases, normalized initial damage stress and Young's modulus also increase, leading to enhanced energy absorption. However, this increase in cell diameter negatively affects the energy absorption efficiency, resulting in increased instabilities. A finite element analysis was conducted using the LS-DYNA finite element software to investigate the behavior of aluminum foils under all the experimentally tested loading regimes. The simulation results reveal that the deformation zone formed due to collapse diminishes with increasing cell diameter. More importantly, a new damage mechanism named central cell cleavage was reported, which increased the energy absorption capacity and amplified the instability during deformation. This study offers novel insights into the mechanical behaviors exhibited by aluminum foams, thereby facilitating their application in structural engineering.

Quasi-static axial crushing investigation of filament-wound eco-friendly energy-absorbing glass fiber and jute fiber composite structures

This study conducts a comparative analysis of glass fiber (GF) and jute fiber (JF) as energy-absorbing filament wound eco-friendly structures under quasi-static axial crushing with varying wall thickness, starting with a 2-layer configuration and progressing to 4 and 6 layers. Three primary failure modes, fiber-matrix fracturing, local buckling, and delamination were observed. Both JF and GF 2-layer configurations showed less progressive failure due to their lightweight nature, with crush force efficiency (CFE) of 0.44–0.46 and specific energy absorption (SEA) of 4.4–5.1 J/g, raising considerations for crash scenarios involving human safety. The 4-layer JF configuration demonstrated a significant increase in IPF to 3496 N, effectively restricting buckling and brittle fracture and leading to a higher SEA of 12.61 J/g. In comparison, the GF 4-layer configuration exhibits lower initial peak force (IPF) and SEA values but a higher CFE value of 0.64 at a lower weight of 58 g. The 6-layer JF configuration attains increased stability in load-bearing capacity with a CFE of 0.84 but at the cost of a high weight of 128 g. On the other hand, the 6-layer GF configuration showcases a higher SEA of 10.5 J/g with a moderate CFE of 0.75 and slightly lower weight, suggesting a delicate balance between performance and weight. Visual examination revealed dominant failure modes as local buckling in GF and brittle fracturing in JF configurations. Overall, the 4-layer configurations of JF and the 6-layer configuration of GF composite tubes demonstrate exceptional energy absorption efficiency, suggesting the potential for exploring hybrid configurations to achieve a balanced crashworthiness performance.

Effect of Aspect Ratio, Rotation, and Eccentricity of Square Section Nested Thin-Walled Tubes on Their Energy Absorption Characteristics Under Quasi-Static Load

In this research, energy absorption characteristics of nested thin-walled aluminum structures with square cross-section have been investigated, and the effect of the three parameters: eccentricity, rotation, and tube aspect ratio on the energy absorption characteristics of the structure has been studied. The properties investigated were the specific energy absorption and crush force efficiency. An aluminum 1050 sheet was used to build the tubes. After making the samples and determining how the tubes were placed with each other, the structures were subjected to quasi-static axial loading. Also, for parametric investigations, the behavior of the structures was simulated using LS-Dyna software. The results showed that the simultaneous effect of the three desired parameters has increased the specific absorbed energy and the crushing force efficiency. When the tubes were at maximum eccentricity, the specific energy absorption and crushing force efficiency increased by reducing the aspect ratio and rotation angle. On average, the best sample’s specific energy absorption and crush force efficiency increased by 41.9% and 22.2%, respectively, compared to the single tube.

Energy absorption characteristics of novel bionic H-type whip restraints for nuclear power plants

To enhance the efficiency of energy absorption in H-type whip restraints for nuclear power plants, this study takes inspiration from the asymmetric twisted lines observed in the Nautilus shell, introducing the Nautilus Bionic Hierarchical Multi-Cell (NBHMC) structure. For different high-energy pipeline sizes and energy absorption quantities, the proposed structures are miniaturized and can be combined into H-type whip restraint by multiple tubes to meet the requirements. The NBHMC structures are investigated based on the validated finite element method, the results demonstrate that the energy absorption per unit mass of the new structure can reach up to 180% of that of the hollow tube, with the maximum enhancement in energy absorption efficiency being 47%. Through parameter analysis of the cross-sectional wall thickness, the highest energy absorption efficiency obtained is 99.62%, with a specific energy absorption of 31.29J/g. Furthermore, utilizing the TOPSIS method, all proposed parameter combinations are ranked, leading to the determination of the optimal parameter combination. Additionally, a theoretical model predicting the mean crushing force is introduced, exhibiting good agreement with numerical simulations. The results presented in this work provide innovative insights for the design of efficient pipe whip restraints.

Study on the influencing factors of impact resistance of shear thickening fluids filled foam

PurposeThe present study assesses the impact resistance of the shear thickening fluids-filled (STFs-filled) foam through drop-hammer impact tests.Design/methodology/approachThe maximum residual impact load and specific impact energy absorption rate of STF-filled foam are studied with varying thickness (4–14 mm), densities (0.35–0.6 g/cm3) and hardness (40–50 Rockwell Hardness C Scale (HRC)) under different ambient temperatures (−20−20 °C) and impact energies (25–75 J).FindingsThe following conclusions are obtained from this study: (1) the higher the impact energy, the greater the maximum residual impact force and energy absorption efficiency of the material; (2) the impact resistance of STF-filled foam can be improved with the decrease of ambient temperature, achieving the highest energy absorption rate at −10?. (3) STF-filled foam substrate has the highest impact resistance, the lowest maximum residual impact force and the highest energy absorption coefficient when the density is 0.35 g/cm3, the hardness is 45HC and the thickness is 10 mm.Originality/valueThis is the first paper to analyze the impact of both environmental factors and material properties on the impact resistance of STF-filled foam. The results show that the decrease in temperature and the increase in hardness can enhance the impact resistance of STF-filled foam.

Origami-based bidirectional self-locking system for energy absorption

When a periodic cellular structure is subjected to high-intensity loading, lateral splashing can occur, significantly decreasing macro mechanical properties. Periodic structures with self-locking properties can overcome this inherent flaw and achieve excellent performance characteristics, including high energy absorption efficiency. In this regard, thin-walled periodic self-locking dissipative structures have been extensively studied recently. Most existing bend-dominated self-locking dissipative systems are two-dimensional and can only achieve self-locking under specific loading conditions. This paper describes a three-dimensional origami-based bidirectional self-locking system that can achieve self-locking under normal and shear loading. Furthermore, a plastic hinge model revealed the energy absorption mechanism of the origami-based cells, whose specific energy absorption (SEA) is higher than that of other existing bend-dominated self-locking cells. The bidirectional self-locking of the origami-based system was demonstrated through compression, bending and impact tests. This origami-based system has high energy absorption efficiency, and the novel bidirectional self-locking mechanism can significantly broaden the design space for periodic dissipative metamaterials.

Elastic wave suppression through additively manufactured petal lattice metamaterials

Lattice-core sandwich structure metamaterials are lightweight alternatives to monolithic materials that can present better mechanical, thermal, and energy dampening performance. Manufacturing lattice metamaterials to follow curved surfaces can pose a challenge, as the lattices rely on their geometric orientation to the substrate for their mechanical properties. This work rationally designed a lattice structure where the surface is broken up into “petals” connected to the underlying lattice, which localizes the petals’ impact response. This design opens a pathway for implementation of lattice-core sandwich structures onto complex surface geometries. These petal structures were evaluated for their energy absorption efficiency experimentally by utilizing pressure waves generated with nanosecond lasers and computationally via finite element modeling. The lattice structures exhibited a two-orders-of-magnitude decrease in transmitted pressure compared to their constituent steel at equivalent mass. Furthermore, localizing energy absorption into petal structures provided a 44% reduction in peak load compared to a continuous “single-petal” design.

Effect of thin-wall copper on the mechanical properties of ultra-light 3D-printed polymeric sandwich panels

In this study, a portion of an ultra-light polymeric sandwich panel was produced by additive manufacturing with a dimension of 25 × 25 × 37 mm as a precursor. Then, the precursor was covered with a thin-walled copper through electroforming deposition as a portion of a copper sandwich panel. The weight of the polymeric sandwich panel increased from 2–4 g to 9–13 g for the copper sandwich panel during the electroforming process. Compressive strength and energy absorption density of the polymeric and the copper sandwich panels with open-cell cores measured for 4, 5 and 6 PPI. The results shown that the ultra-light polymeric and copper sandwich panels with 6 PPI have the best mechanical performance in terms of yield stress, energy absorption density and energy absorption efficiency. Moreover, the abovementioned characteristics are 0.09 MPa, 0.11 MJ . m − 3 and 80% for the polymeric sandwich panels, and 1.74 MPa, 0.98 MJ . m − 3 and 70% for the copper sandwich panels, respectively. Therefore, the addition of 9.01 g copper as a reinforcing around the core’s polymeric ligaments caused an increase in the yield stress for 20 times and in the energy absorption density for 9 times. Comparing to Ashby diagram, and previous studies, the sandwich panel portions of this study could develop the industry of sandwich panels by using the metallic shells as a reinforcement to ultralight polymeric sandwich structures.

Multi-freedom effects on a raft-type wave energy convertor- hydrodynamic response and energy absorption

This research delves into the effects of multiple degrees of freedom on a raft-type wave energy converter (WEC), using both experimental and computational methods. The WEC features two interconnected floating bodies linked by a specialized parallelogram joint, allowing for distinct heave, pitch, and surge motions. The power take-off (PTO) system, integrating Coulomb damping, is analysed for its impact on energy absorption. Despite varying damping amplitudes, peak energy absorption is consistent across different wave periods, as shown in scaled model tests. Computational simulations further investigate the multi-freedom effects by imposing constraints on various degrees of freedom, thus elucidating their individual and combined influences on energy absorption. Preliminary results indicate that the addition of degrees of freedom can enhance the WEC's efficiency, especially through coordinated release of the bodies' relative pitch and surge motions. The study also finds that the energy absorption efficiency from pitch motion depends on the release of surge motion. Moreover, the energy distribution among each degree of freedom is significantly affected by the device's multi-freedom characteristics. This research provides valuable insights and practical guidelines for the development of advanced multi-freedom WEC technologies.

Ballistic performance and energy transfer of ultrahigh molecular weight polyethylene laminate

Soldier protection is crucial in contemporary localized conflicts, However, the impact response mechanism of UHMWPE laminate as the insert plate of ballistic helmet and bulletproof vest is still unclear. This study utilized 3D-DIC technology to analyze the impact response of UHMWPE laminates subjected to a 9 mm lead-core pistol bullet at a velocity of 334.93 m/s. The damage mode and response characteristics of the back surface were revealed; an effective numerical calculation method was established and could reveal the energy conversion process. The bullet penetrated the front face with 1.01 mm, resulting in a cross-shaped failure feature due to fiber bundle compression and aggregation. The numerical model confirmed its accuracy by comparing the height, width, and inplane strain distribution within the inplane of the bulge with experimental results. It further investigated the interaction between the bullet and the laminate, and energy transformation. The bullet's kinetic energy decreased by 80.64 %, in which the laminate absorbs 30.84 % of the bullet's energy as internal energy and 35.06 % as kinetic energy, meanwhile the bullet's internal energy increases by 11.77 %. The results show the damage mode and energy transformation of laminate, which provides theoretical support for revealing the impact response mechanism and improving the protective energy absorption efficiency.

Velocity match between plasma and flame in microwave-assisted spark ignition

As a prospective ignition technique, microwave-assisted spark ignition (MAI) can accelerate flame and thus satisfy the demand for effective ignition. However, its acceleration mechanism on flame velocity is still unclear, which hinders its application and optimizations. Therefore, this research focuses on understanding the flame acceleration mechanism behind MAI. In this paper, MAI is achieved through radiating a microwave pulse after spark ignition. The flame velocity and the precise absorbed energy under different combustion conditions are investigated with flame kernel's Schlieren images and microwave energy diagnostics, respectively. The results show that MAI accelerates flame primarily by the interaction between microwave plasma and flame front, rather than the free electrons within the flame. Specifically, microwave accelerating flame takes two processes: energy absorption, and velocity match. Energy absorption refers to the microwave energy absorbed by residual electrons after ignition to generate and sustain microwave plasma, while velocity match involves the outward plasma with faster velocity propelling the slower flame front. Moreover, the plasma velocity shows a positive relationship with absorbed microwave energy. The velocity match between microwave plasma and flame is important to successful flame acceleration. Besides, the efficiency of energy absorption and flame acceleration varies with plasma type (glow or incandescent). Glow plasma is characterized by effective flame acceleration but relatively low absorption efficiency, and incandescent plasma is in reverse. The maximum absorption efficiency can be elevated to 70 % with incandescent plasma occurring. Ultimately, the plasma velocity declines with its traveled distance, which might impair the flame acceleration.

Repeated impact response of honeycomb sandwich panels based on the failure parameters of adhesive layer and material

Honeycomb sandwich structure has been widely used in lightweight and impact protection of rail vehicle structures due to its excellent mechanical properties. In this paper, the plastic deformation, failure response and energy absorption characteristics of honeycomb sandwich panels for rail vehicles under repeated impact loads were studied. The three-point bending tests and low-speed impact tests of honeycomb sandwich panels were carried out, and a three-dimensional numerical model considering the detailed structure of the honeycomb core and the failure of the adhesive layer was established. The model can reasonably simulate honeycomb sandwich panels’ stiffness, strength, and structural failure. The effects of impact times and impact angle on the performance indexes of the honeycomb sandwich panel were studied. The results show that when the impact energy is the same, the impact times will affect the energy absorption distribution of honeycomb sandwich panels. With the increase in impact times, the panel’s absorption energy decreases, the core’s absorption energy increases, and the total absorption energy decreases. For multiple impact conditions, with the increase of impact times, the single energy absorption of the upper panel and core decreases, and the single energy absorption of the lower panel increases. When the impact energy is the same, the rise in impact angle will increase the damage to the honeycomb sandwich panel, and the energy absorption of each part will increase. In addition, the influence of impact times on the energy absorption efficiency of honeycomb sandwich panels is related to the impact angle.

Study on the crashworthiness of multi-cell thin-walled tubes filled with triply periodic minimal surface lattices

To improve energy absorption and efficiency and develop a structure with outstanding energy absorption capability, this study proposed designing multi-cell tubes filled with triply periodic minimal surface (TPMS) lattices. Based on experimental and simulation methods, the crashworthiness of multi-cell tubes filled with three types of TPMS lattices (Diamond, Gyroid, and Primitive) was investigated. Five multi-cell tube structures were fabricated by increasing the thin-walled tube corner units, improving the energy absorption efficiency by 67.98%. The results show that due to the coupling between TPMS lattices and thin-walled tubes, multi-cell tubes filled with TPMS lattices exhibited better crashworthiness performance. The energy absorption of multi-cell tubes filled with Diamond, Gyroid, and Primitive lattices increased sequentially. The energy absorption per unit mass and energy absorption capability were most notably enhanced for the multi-cell tubes filled with Diamond lattice, with energy absorption efficiency 17.24% higher and energy absorption 104.26% greater than empty multi-cell tubes. This inspires crash designs of rail vehicles and automotive fronts.

Energy Absorption Capability of Graded Hybrid Triply Periodic Minimal Surface Structures Based on Fracture Zone Controlling

A novel design strategy of the graded hybrid energy‐absorbing lattice structure is proposed by controlling fracture zone. The primitive (P) and iWP (W) structures are two kinds of triply periodic minimal surface structures with typical deformation and failure modes. Thus, taking the P (stretching‐dominated) and the W structures (bending‐dominated) as object, the deformation and failure mechanisms of two structures are studied. Then, the PWP (i.e., the fracture zone of the P structure filling with the W structure) and WPW (i.e., the fracture zone of the P structure filling with the W structure) structures with uniform and gradient change are designed. The structures are fabricated using stereolithography appearance process and compressed under quasistatic conditions. And the energy absorption capacity comparison of these structures is studied. The experimental results show that the maximum energy absorption efficiency of the PWP structure is 38.85% higher than that of the P structure and the densification energy absorption of the WPW structure is 66.67% higher than that of the W structure. Additionally, gradient design can effectively improve the densification energy absorption of lattice structure. The novel structural design greatly contributes to customized energy absorption design of lattice structures.

Gas-particle-heat dynamic coupling simulation in directed energy deposition

Powder flow can affect the temperature variations in directed energy deposition (DED). However, the direct coupling mechanism remains unknown. To solve this problem, the heat and mass transfer in additive manufacturing was simulated using dynamic coupling. The interactions between the multiphase flow and heat transfer were established. A comparison with experiment shows that the accuracy of the predictions of the numerical simulation regarding powder size distributions and temperature increases is higher than 95 %. The average temperature increase of the metal powders with different weight functions was highly consistent in the simulation process. As the powder size increases, the average temperature of the powder on the printing plane decreases. This was the reason for the formation of a deeper melt pool in the case of smaller particles in the experiment. The different curvatures between the particle surface and melt pool surface lead to a decreased energy absorption efficiency in DED. The relationship between the powder features and the melt pool size was studied. A decrease in the powder flow rate increased the temperature, leading to a larger melt depth.

Numerical studies of the energy absorption capacities and deformation mechanisms of 2D cellular topologies

This paper investigates the energy absorption capacities of selected cellular topologies under quasi-static loading conditions. Twenty topologies with nearly identical relative densities belonging to 4 groups were examined: honeycomb, re-entrant, bioinspired and chiral. The topologies were modeled using an experimentally validated numerical ABSplus model and subsequently subjected to in-plane uniaxial compression tests. The findings revealed the topologies with the most favorable energy absorption parameters and the main deformation mechanisms. The topologies were classified by mechanism, and a parametric study of basic material properties, namely modulus of elasticity, yield stress, and ductility, was performed for a representative topology from each mechanism. The results indicated that the honeycomb group topologies were characterized by the largest average absorbed energy, and yield stress was found to have the greatest impact on energy absorption efficiency regardless of the main deformation mechanism.

Parametric design and performance evaluation of gyroid triply periodic minimal surface preparation by LCD photopolymerization

In this paper, the Gyroid triply periodic minimal surface is prepared by liquid crystal display photopolymerization technology, and 10 models of the periodic parameter T in [1/5, 2] are designed. Using the method of finite element method and experimental verification, when T = 1/3, there are fewer stress concentration areas on the Gyroid surface, the number of grids is moderate, the compression crush rate is the smallest, and the porosity error is reasonable. Through the microscopic morphology, it is found that the surface, after printing, forms gear shape and resin residue so that the actual volume is larger than the theoretical volume, and the porosity is minor. Keeping periodic parameter T = 1/3 and porosity of 50%, four kinds of Gyroid surface structures were designed by changing the parameter surface offset, wall thickness, offset thickness, and gradient arrangement. The effects of different loading directions on its mechanical properties, deformation behavior, and energy absorption were discussed through compression experiments. The results show that the vertical load is applied to form a fault zone from the upper left angle to the lower right angle of 45°, and the parallel load is applied to create a fault zone from the upper right angle to the lower left grade of 45°. When the load is used in the vertical direction, the energy absorption and energy efficiency of the surface offset Gyroid surface are the largest. When the load is applied in the parallel order, the energy absorption curves of the four structures change similarly, and the deformation amplitude of the wall thickness Gyroid surface during the compression process is relatively stable. The energy efficiency of gradient arrangement Gyroid surface increases fastest in the compaction stage.

Theoretical analysis and crashworthiness optimization of multi-cell Al-CFRP hybrid tube

In this paper, a hybrid thin-walled tube with multiple cells and multiple materials is proposed to achieve lightweight, high energy absorption efficiency, and low cost of structures. Energy absorption characteristics and crushing deformation of the hybrid structures are investigated by experimental testing and numerical analysis. Meanwhile, theoretical prediction models of the mean crushing force for hybrid structures are developed and its accuracy was verified. It is found from the sensitivity analysis that the parameters of the multi-cell structure have significant effects on energy absorption. Furthermore, the multi-objective optimization including surrogate models is performed to obtain optimal crashworthiness of the multi-cell hybrid tube. The same optimal results were obtained using the full factor response mapping optimization algorithm and the non-dominated sorting genetic algorithm with elite strategy algorithm for multi-objective optimization solution. Compared with the original multi-cell hybrid tube and multi-cell pure aluminum (Al) tube, the optimized structure showed an increase of 0.25% and 25.31% in specific energy absorption, an increase of 16% and 77.34% in average crushing force, and an increase of 3.89% and 23.08% in energy absorption efficiency, respectively.

A Synergistic Approach Combining Surface Enhancement and Buckling Modes for Improved Axial Crushing Performance of Thin-Walled Tubes

Abstract In this study, thin-walled tubes were circumferentially strengthened by plasticity ball burnishing of critical locations determined from buckling mode analysis. Axial crush test results revealed that the surface-treated (ST) tubes increased localized yield strength, attained superior crashworthiness performance, and triggered predictable deformation modes according to the buckling modes of the tubes. Numerical analysis was performed and successfully validated with the experiment at 90% prediction accuracy. The treated tube ST-4 with the 12th buckling mode outperformed a conventional tube with an increase in specific energy absorption (SEA) and crush force efficiency (CFE) by up to 70% while sustaining a low increase in initial peak force (IPF). Furthermore, the tube demonstrated a greater rate of energy dissipation compared to tubes with conventional surface-treated patterns at the same level of surface-treated area. The crashworthiness performance improved as the surface-treated area ratio increased. A theoretical model was developed for the surface-treated tube based on fundamental deformation kinematics, predicting mean crushing force and total energy absorption with acceptable accuracy. The findings strongly suggest that the proposed surface-enhanced tubes have great potential to be used as energy-absorbing structures in crashworthiness applications.

Mechanical Properties and Failure Behavior of Epoxy Rubber Powder Composites Reinforced with Hollow Beads

In this paper, new epoxy resin/rubber powder/hollow beads three-phase composites were prepared by designing the incorporation of fly ash hollow beads with different mass fractions (5%, 10%, 15%, and 20%) as new reinforcing phases into epoxy resin/rubber powder two-phase composites with 5% mass fraction of carbon black rubber powder. Quasi-static compression tests were conducted at room temperature to test the compressive properties of the oxygen resin/rubber powder/hollow beads composites. Calculate the energy absorption properties and energy absorption efficiency of the composites from the compression curves. Fracture characteristics of compressed material specimens with microscopic morphology were observed by scanning electron microscopy. By systematically analyzing the effect of fly ash hollow beads content on the mechanical properties of epoxy resin/rubber powder/hollow beads three-phase composites, it was found that fly ash hollow beads as reinforcing materials can effectively improve the brittleness and yield strength of epoxy resin/rubber powder as well as the energy-absorbing properties and efficiency of the composites. The energy absorption properties of the epoxy resin/rubber powder/hollow beads composites increased and then decreased with the increase in the mass fraction of fly ash hollow beads. In the epoxy resin/rubber powder/hollow beads composites, the most significant performance was observed when the mass fraction of fly ash was 10%.