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Abstract Metal foam is light in weight and exhibits an excellent impact-absorbing capability. Laser forming has emerged as a promising process in shaping metal foam plates into desired geometry. While the feasibility and shaping mechanism has been studied, the effect of the laser forming process on the mechanical properties and the energy-absorbing behavior in particular of the formed foam parts has not been well understood. This study comparatively investigated such effect on as-received and laser-formed closed-cell aluminum alloy foam. In quasi-static compression tests, attention paid to the changes in the elastic region. Imperfections near the laser-irradiated surface were closely examined and used to help elucidate the similarities and differences in as-received and laser-formed specimens. Similarly, from the impact tests, differences in deformation and specific energy absorption were focused on, while relative density distribution and evolution of foam specimens were numerically investigated. 

Abstract Metal foam sandwich panels have been the subject of many concept studies, due to their exceptional stiffness, light weight, and crash absorption capacity. Yet, the industrial production of the material has been hampered by the fact that it is challenging to bend the material into practical engineering shapes. Only recently, it has been shown that bending of metal foam sandwich panels is possible using lasers. It was also shown that the material can be bent into Euclidean (2D) geometries, and the governing laser-induced bending mechanisms were analyzed. This study was focused on laser forming of metal foam sandwich panels into non-Euclidean (3D) geometries. It was investigated whether the bending mechanisms and process parameters identified for 2D laser forming translate to 3D deformation. Additionally, the impact of the laser scan length was determined by comparing different scan patterns that achieve the same 3D geometries. It was shown that laser forming could induce 3D deformation necessary for both bowl and saddle shapes, the two fundamental non-Euclidean geometries. The amount of laser-induced bending and in-plane strains vary depending on process conditions and the governing bending mechanisms. Lastly, the laser scan length was shown to become more important for metal foam sandwich panels, where the panel thickness tends to be large.