Dynamic behaviour of lightweight automotive materials

With the demand of sustainable development in the automotive industry, reduction of weight and increase of safety have been on the schedule for a long time and will be the core issues to pursue for manufacturers. Replacement of traditional materials using lightweight alternatives with high energy absorption capacities is a major strategy to achieve this goal. The mechanical properties of lightweight automotive materials under quasi-static and low strain rate (10-4 to 1 s-1) and high strain rate (>102 s-1) loadings are widely studied in the past decades. However, study on the mechanical properties of these materials in the intermediate strain rate region (1 to 102 s-1, typical in a car crash) is limited. Therefore, filling the strain rate gap between low and high strain rates becomes important and valuable for industrial design. In this study, the dynamic behaviour of three types of materials was studied within a wide range of strain rate, namely aluminium foams, aluminium honeycombs and twinning induced plasticity (TWIP) steels, with an emphasis on the intermediate strain rate loadings through reliable experimental data under constant compressive and tensile velocities. In-depth discussion on the strain rate effect of these materials was made and a simple analytical solution for the entrapped air contribution to the strength enhancement of honeycombs was proposed. Finite element modelling (FEM) of the crushing behaviour of honeycombs under constant velocity was then conducted to investigate the deformation patterns and the high strain rate (>103 s-1) impact behaviour of honeycombs. It has been found that both the relative density and the strain rate have great influence on the dynamic mechanical properties of cellular materials. Closed-cell metallic foams were found to be sensitive to the strain rate in the intermediate strain rate region (1 to 102 s-1), as are the metallic honeycombs under out-of-plane compression. Semi-empirical relations were obtained by fitting experimental data. It was shown that the plateau stress has power law

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