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Are aluminum foam sandwich composites (AAS) suitable as structural materials for battery enclosures in terms of protection against thermal runaway and structural integrity? To address this, mechanical and thermal stress tests were conducted. Samples were subjected to bollard tests, flame tests, and particle impact tests. During the flame and particle impact tests, temperature fields, deformations, and intrusion behavior were recorded. Bollard tests simulated intrusion loads, and force displacement curves were evaluated. The results of the fire and particle impact tests demonstrate the thermal shielding provided by the foam material. Furthermore, the AAS composite structures exhibited significant energy absorption and damping.
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