Properties of metal/epoxy foam hybrid structures

Foam-filled (hybrid) tubular structures have been shown to achieve a considerable amount of weight saving while maintaining the crashworthiness. Most of these studies were carried out in axial compression using tubular structures made of conventional metals (e.g. mild steel, stainless steel, 6000 series aluminium alloy). However, with the advent of new materials such as advanced high strength steel (AHSS), Ultra High Strength Steel (UHSS), and high strength aluminium alloys (e.g. 7000 series), hollow (empty) structures can be designed with thinner walls to achieve similar or better crashworthiness. Currently, such tubular structures are being used as door intrusion beams for side impact protection in the automobile industry.