Quasi Static Compressive Behavior of Al-Si-SiC-xFe Foam Filled Crash Boxes

The effect of iron on the structure and absorbed energy in thin-walled brass tubes filled with Al-Si-SiC-xFe foams, produced through powder metallurgy rout, during uniaxial compressive loading was evaluated. Results showed that by increasing the iron content up to 3 wt.% will increase the sphericity of the cells, foam density and homogeneity of the structure. However, the formation of Al4Fe2Si intermetallic and micro-shrinkage in the cell walls and edges resulted in a decrease in the magnitude of the absorbed energy. Moreover, according to experimental data, a model was developed based on the relative density of the foam along with the geometry of the foam and tube. This model was used to predict the energy absorption of foam filled tubes.