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<p>Lightweight, impact-attenuating foams that can dissipate large amounts of kinetic energy are essential for modern helmets, automotive knee-bolsters, and blast-mitigation panels, where every added gram reduces wearer fatigue or fuel consumption while safety requirements continue to rise. However, conventional polyurethane foam has limitations in resisting sudden deformation under high-impact forces. To address this gap, the present work evaluates polyurethane foam impregnated with a shear-thickening fluid (STF) that contains 0–1.2 wt % multi-walled carbon nanotubes (MWCNT), with the goal of identifying the optimum formulation for peak-force mitigation and energy-damping efficiency. STF with 1.2 wt % MWCNT achieved the highest peak viscosity (188.41&#xa0;Pa · s), delivering an optimal shear-thickening response. Foam treated with this formulation exhibited a 35% reduction in peak force and a 29% increase in impulse during 1.3&#xa0;m drop tests (1200&#xa0;g mass) compared with untreated foam, while SEM revealed only minor cell-wall distortion. These findings demonstrate a practical pathway to engineer ultralight, high-performance impact-mitigation foams for personal protective equipment and transportation safety systems, and lay the groundwork for future studies on cyclic durability, fire behaviour, and large-scale manufacturing of STF-nanotube-reinforced foams.</p>

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Enhanced Impact Resistance of Polyurethane Foam Composites Reinforced with Shear Thickening Fluids and Multi Wall Carbon Nanotubes

  • 期刊论文

  • 发表日期：

    2025年7月1日

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  • Andoko Andoko,
  • Riduwan Prasetya,
  • Madina Ismail,
  • Rio Anugrah Vidyanto,
  • Poppy Puspitasari,
  • Mohammad Sukri Bin Mustapa

摘要

Lightweight, impact-attenuating foams that can dissipate large amounts of kinetic energy are essential for modern helmets, automotive knee-bolsters, and blast-mitigation panels, where every added gram reduces wearer fatigue or fuel consumption while safety requirements continue to rise. However, conventional polyurethane foam has limitations in resisting sudden deformation under high-impact forces. To address this gap, the present work evaluates polyurethane foam impregnated with a shear-thickening fluid (STF) that contains 0–1.2 wt % multi-walled carbon nanotubes (MWCNT), with the goal of identifying the optimum formulation for peak-force mitigation and energy-damping efficiency. STF with 1.2 wt % MWCNT achieved the highest peak viscosity (188.41 Pa · s), delivering an optimal shear-thickening response. Foam treated with this formulation exhibited a 35% reduction in peak force and a 29% increase in impulse during 1.3 m drop tests (1200 g mass) compared with untreated foam, while SEM revealed only minor cell-wall distortion. These findings demonstrate a practical pathway to engineer ultralight, high-performance impact-mitigation foams for personal protective equipment and transportation safety systems, and lay the groundwork for future studies on cyclic durability, fire behaviour, and large-scale manufacturing of STF-nanotube-reinforced foams.