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<p>Side-impact safety remains a critical challenge for electric vehicles, particularly in terms of protecting battery systems and occupants. This study investigated the optimization of an aluminum–foam protective cross-section installed to enhance side-impact resistance. A structure consisting of a 10-mm Al 6061-T6 aluminum shell filled with closed-cell aluminum foam was analyzed across six geometric configurations, including single and double, hollow, and foam-filled designs. The flexural performance was evaluated using three-point bending finite element simulations and validated through experimental testing. The results show that the foam-filled double-layer configuration achieved the highest flexural strength (38.44&#xa0;MPa), whereas the hollow single small configuration exhibited the lowest performance (20.49&#xa0;MPa). ANOVA confirmed that the geometric and material parameters significantly influenced the structural behavior, with the foam-filled double-layer design demonstrating superior bending stability. These findings identify an optimal lightweight configuration for improving battery side-impact protection in electric vehicles.</p>

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Flexural performance of aluminum–foam protective structures for electric vehicle battery side-impact protection

  • 期刊论文

  • 发表日期：

    2026年7月2日

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  • F. Djamaluddin

摘要

Side-impact safety remains a critical challenge for electric vehicles, particularly in terms of protecting battery systems and occupants. This study investigated the optimization of an aluminum–foam protective cross-section installed to enhance side-impact resistance. A structure consisting of a 10-mm Al 6061-T6 aluminum shell filled with closed-cell aluminum foam was analyzed across six geometric configurations, including single and double, hollow, and foam-filled designs. The flexural performance was evaluated using three-point bending finite element simulations and validated through experimental testing. The results show that the foam-filled double-layer configuration achieved the highest flexural strength (38.44 MPa), whereas the hollow single small configuration exhibited the lowest performance (20.49 MPa). ANOVA confirmed that the geometric and material parameters significantly influenced the structural behavior, with the foam-filled double-layer design demonstrating superior bending stability. These findings identify an optimal lightweight configuration for improving battery side-impact protection in electric vehicles.