DYCOMP - ECCCS – 3 2024

Experimental and numerical assessment of hybrid composite crash structures offering increased sustainability

  • Dalli, Denis (FEUP)
  • Arteiro, Albertino (FEUP)

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Energy absorption structures in high performance motorsport and aerospace applications are ever-increasingly manufactured from carbon fibre reinforced polymer (CFRP) material systems. Several new composite materials have been recently introduced to the market, including thin-ply CFRPs and more environmentally sustainable alternatives, such as thermoplastics and natural fibre composites (NFCs). There is a noticeable knowledge gap about the energy absorption capabilities of these novel materials, limiting their potential introduction to the design of such structures. While it is known that NFC materials such as flax fibre thermosets possess significantly lower mechanical properties (e.g. compressive strength) compared to high-grade CFRPs, energy absorption is not a simple reflection of these base properties, and thus such materials should not be disregarded at first glance. Furthermore, through laminate hybridisation, there is a realistic potential of matching the energy absorption offered by classical CFRPs while incurring a minimal weight penalty and simultaneously improving the sustainability of the structure. The present work aims to study the crashworthiness performance of hybrid composite laminates manufactured from thermoset NFCs and CFRPs. A quasi-static experimental study was performed on both monolithic and hybrid laminate tubular coupons of various curvatures. These were crushed in a stable progressive manner, enabling the determination of a steady-state crush stress plateau. Significant improvements were noted in the energy absorption levels of both monolithic flax and hybrid laminate coupons, in comparison to those presented in literature. Furthermore, a hybrid laminate Formula 1 Side Impact Structure (SIS) was manufactured and tested quasi-statically in collaboration with McLaren Racing, as a first demonstration of the potential use of NFCs in similar crashworthiness applications.