Static Mechanical Properties of Expanded Polypropylene Crushable Foam

Closed-cell expanded polypropylene (EPP) foam is commonly used in car bumpers for the purpose of absorbing energy impacts. Characterization of the foam's mechanical properties at varying strain rates is essential for selecting the proper material used as a protective structure in dynamic loading application. The aim of the study was to investigate the influence of loading strain rate, material density, and microstructure on compressive strength and energy absorption capacity for closed-cell polymeric foams. We performed quasi-static compressive strength tests with strain rates in the range of 0.2 to 25 mm/s, using a hydraulically controlled material testing system (MTS) for different foam densities in the range 20 g/dm³ to 220 g/dm³. The above tests were carried out as numerical simulation using ABAQUS software. The verification of the properties was carried out on the basis of experimental tests and simulations performed using the finite element method. The method of modelling the structure of the tested sample has an impact on the stress values. Experimental tests were performed for various loads and at various initial temperatures of the tested sample. We found that increasing both the strain rate of loading and foam density raised the compressive strength and energy absorption capacity. Increasing the ambient and tested sample temperature caused a decrease in compressive strength and energy absorption capacity. For the same foam density, differences in foam microstructures were causing differences in strength and energy absorption capacity when testing at the same loading strain rate. To sum up, tuning the microstructure of foams could be used to acquire desired global materials properties. Precise material description extends the possibility of using EPP foams in various applications.