This study presents experimental results on the behaviour of aluminium alloy metal structures and foams manufactured by lost-wax casting and using 3D printed components for internal structure definition. Results for tensile tests, metallurgical properties, surface quality and geometry tolerances were obtained and discussed. The analysis focused on development geometries, used for adjusting manufacturing parameters and prototype geometries intended for geometrical and mechanical validation. The results are indicative of the viability of the method for producing foam structures suitable for mechanical loading.

This study presents an approach for the improvement of crashworthiness properties of aluminium tubular structures using initiators introduced through localized heating. The main objective of this approach is to improve the ability to absorb impact energy in a progressive and controlled manner by a local modification of material properties. Through a localized heating in areas previously chosen for initiation, associated with the softening of the aluminium alloy the deformation can be introduced precisely, forcing the tubular structure to deform in a mode of high energy absorption and reducing the maximum load in a controlled manner. This study presents the properties for an aluminium alloy 6061-T5 modified by thermal treatment by the use of a laser beam. Experimental results are presented of quasi-static and impact tests of tubular structures using the proposed approach. This concept appears as possible and effective in the experimental work presented.