The physical mechanisms underlying the beneficial effect of filling aluminum foams
into the interstices of corrugated plates made of stainless steel were explored with
finite element (FE) simulations. Relative to unfilled corrugated plates of
equal mass, this effect was assessed on the basis of elevated peak stress and
enhanced energy absorption under quasistatic out-of-plane compression. Upon
validating the FE predictions against existing measurements, the influence of key
geometrical and material parameters on the compressive response of foam-filled
corrugated plates was investigated. Different from the traditional buckling
modes of empty corrugations, four new buckling modes were identified for
foam-filled corrugations. Based upon these deformation modes of post-buckling,
collapse mechanism maps were constructed. Due to the additional resistance
provided by foam filling against buckling of the corrugated plate and the
strengthening of foam insertions due to complex stressing, both the load
bearing capacity and energy absorption of foam-filled sandwiches were greatly
enhanced.
Keywords
foam-filled corrugated core, finite element method,
buckling, collapse mechanism