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Thermomechanical behavior of open-cell polyurethane foam for energy absorption
Furst, Andrew James
Furst, Andrew James
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2025
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2026-11-11
Abstract
Open-cell polyurethane foam is a critical energy-absorbing material used in applications ranging from protective sports gear to military helmet liners due to its ability to undergo large deformations while maintaining relatively low stress. This study characterizes the strain rate and temperature dependence of an open-cell polyurethane foam commercially developed by Team Wendy for use in combat helmet liners. A key focus was the identification and validation of accurate full-field, high-strain measurement techniques using 2D digital image correlation (DIC), which showed that Biot strain and particle tracking of non-straining features aligned with traditional bulk (non-full-field) measurements and provided enhanced insight into localized strain heterogeneity and its evolution under load. With validated metrology, the foam was characterized across quasi-static to dynamic strain rates (10$^{-3}$~s$^{-1}$ to 10$^3$~s$^{-1}$ s$^{-1}$) and temperatures from $-10^\circ$C to $40^\circ$C using a compression Kolsky (or split-Hopkinson pressure) bar with a custom-designed and integrated thermal control system. Results demonstrated logarithmic scaling of plateau stress with strain rate and linear scaling with temperature, consistent with theoretical models. Notably, microscale deformation patterns shifted with strain rate, with reduced boundary constraint effects observed at higher rates. This work establishes a robust methodology for evaluating low-impedance foams and provides foundational data for constitutive modeling efforts aimed at optimizing impact energy absorption in diverse operational environments.
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