Parametric study of the bending properties of lightweight tubular metal/polymer foam hybrid structures

Hybrid structures of the structural epoxy foam Terocore® and circular tubes of different aluminium alloys (6060 T5, 6061 T6 and 7075 T6) were tested in dynamic three-point bending. Energy absorption, deformation and failure were compared to previous quasi-static tests and found to be similar. LS-DYNA was used to model the tube fracture using element erosion, with successful prediction of failure. A parametric study using the validated finite element model revealed the function of the foam and carrier tube is two-fold, both absorbing energy and also increasing the energy absorption of the outer tube by modifying the deformation.