Optimisation of energy absorption of an A-pillar by metal foam insert

The potential of increasing the energy absorption of a CD car A-pillar by an aluminium foam insert was investigated numerically. Physical aluminium foam inserts were produced by the powder metallurgical route on the basis of the numerically optimised geometry, density and location of the foam filler. The manufactured foam inserts were then bonded to the interior of original Ford CD car A-pillars. A central aspect in the investigation was to keep the prototype manufacture compatible with the production line, and the test specimens were therefore assembled at a real production line. The produced foam-based A-pillars were then tested for quasi-static loading conditions. The tests confirmed the numerical simulations by a gain in energy absorption of 30% at the cost of a mere 3% mass increase. The study shows a successful approach to bridge virtual development, foam-insert manufacture and production-line compatibility with the desired structural performance.