Metal/polymer composite cylinders for crash energy absorption applications

The crashworthiness performance and the deformation history of glass fiber reinforced epoxy (GFRP) composite over wrapped aluminum (Al) cylinders with induced holes were experimentally studied. Specimens were fabricated using wet wrapping by hand lay-up process and tested under quasi-static axial compression. Crashworthiness indicators that is, the initial peak load (F-ip), mean crush load (F-m), total absorbed energy (UTHORN, specific absorbed energy (SEA), and crush force efficiency (CFE) of the proposed cylinders were evaluated. The influence of the number of GFRP plies (P), the diameter (d), and number (N) of induced holes on the crashworthiness performance and the deformation history has also been identified. The experimental outcomes showed that the studied parameters have a significant effect on the crashworthiness performance and the deformation history. Increasing "P" increases F-ip, F-m, U, and CFE while decreasing SEA. Inducing holes with "d" up to 8 mm reduces F-ip, F-m, U, SEA, and CFE of GFRP/Al cylinders. After that the trend is reversed for all indicators except for F-ip. GFRP/Al cylinders with "N = 2" exhibits lower F-ip and higher F-m, U, SEA, and CFE than cylinders with "N = 1". Hybridization process and inducing holes could alter Al-cylinders' failure mechanism. The relation between the crashworthiness indicators and the studied parameters has been constructed by response surface methodology (RSM) to be used by the engineering designers. Al-P6-d12-N2 is recommended to be used in crash energy absorption applications that is, energy absorbing device in vehicles.