Optimum design for energy absorption of square aluminium columns with aluminium foam filler

The performance in axial compression of square aluminium columns with alumi nium foam filler has been assessed based upon existing design formulas for average crush force, maximum force and effective crushing distance. Using a n optimisation algorithm, the combination of (1) foam density, (2) column w all thickness, (3) column width, (4) column material strength and (5) total component length giving the component of minimum mass was determined for s pecific cases. It was found that optimum foam filled columns compared to th e traditionary designed non-filled columns showed smaller cross section dim ensions in addition to less weight. As a consequence, mass-, length- and vo lume reductions are possible by utilising foam filler. (C) 2000 Elsevier Sc ience Ltd. All rights reserved.