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Improving vehicle crash, NVH and metal fatigue performance using expanding polymeric foams can be achieved with a systematic approach. By employing a systematic approach with expandable epoxy foams and alternative carriers, the product development process can be significantly reduced. As a result, high strength and lightweight solutions can be designed to improve the structural performance of today's vehicles. This technical paper will examine the key steps in utilizing a systematic approach to selecting, designing and modeling structural expandable epoxy foam solutions used in conjunction with metallic and non-metallic carriers. A review of material properties, alternative designs and finite element modeling methods will allow for a thorough understanding of how expandable epoxy foams can meet the demanding challenges for improved occupant safety, reduced interior noise levels and increased durability at a reduced vehicle weight.

Finite Element analyses and tests are performed in order to verify appropriate use of material models to represent epoxy foam in FEA. Two types of material models are studied that utilize different approaches to model behavior of materials. One uses nominal stress/strain data to depict yield condition. The other uses plastic stress/strain data and von Mises type yield condition. Due to the particular and different behaviors of epoxy foam in compressive and tensile testing, material curves in both compression and tension areas are utilized. After validation of the material model in both compressive and tensile testing, three point bending tests and simulation of foam and composite beams are carried out. Simulations of material failure and interface effects are also discussed.

Advances in the design and manufacturing of Expandable Epoxy Foam Inserts have resulted in a dramatic rise in the use of these technologies for the treatment of structureborne noise and vibration control. The evolution of these technologies has resulted in light weight and cost competitive solutions when compared to changes in primary body structure and surrounding sheet metal. These advances are discussed in detail. A structured, methodical approach to the identification of requirements for vehicle treatments is discussed. Based on these requirements, a process for the evaluation of application designs and the design optimization process are discussed. Validation of both the material technology and the engineering approach are presented through demonstration on actual vehicle applications.