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February 22, 2026Journal of Materials Science Materials in EngineeringOpen Access

Finite element analysis of cell size, porosity, and density effects on aluminum foam crash box performance

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FTFentaw Alemayehu Tesfaye

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Overview

Finite element analysis optimizes energy absorption in aluminum foam crash boxes, suggesting improved vehicle safety.

Key Points

  • This research aims to model and optimize the performance of aluminum foam-filled crash boxes to enhance vehicle safety during collisions.
  • Utilized Finite Element Analysis (FEA) with Digimat-FE for simulations.
  • Evaluated various configurations of closed-cell aluminum foam crash boxes.
  • Analyzed the effects of cell size, porosity, and density on energy absorption capabilities.
  • Smaller cell sizes (10 mm) and lower void fractions (0.15) achieved the highest energy absorption, up to 255 J.
  • Integrating aluminum foam into sandwich structures significantly improved energy absorption compared to traditional aluminum alloy crash boxes.

Cite This Study

Fentaw Alemayehu Tesfaye (2026) studied this question.

synapsesocial.com/papers/699a9d3c482488d673cd30b6https://doi.org/10.1186/s40712-026-00422-z
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