Fibre composite strengthening of thin-walled steel vehicle crush tubes for frontal collision energy absorption

Thin-walled tubes made from metals or fibre–resin composites have been used widely as energy absorbers in structural crashworthiness applications. A relatively recent advent of composite energy absorbers are externally fibre-reinforced metal tubes, where fibres are bonded to the metal tube surface. Such composites take advantage of the favourable characteristics of each material, being the stable, ductile plastic collapse mechanism of the metal and the high strength to weight ratio of the fibre–resin composite. While several recent experimental and analytical studies have highlighted the substantial improvements in performance fibre strengthening provides, the potential use of such members as structural components in vehicles has yet to be explored. This paper presents a numerical study of the application of fibre strengthened steel tubes to the frontal crush tubes of two different passenger vehicles under frontal collisions. Substantial improvements in vehicle crash performance are demonstrated, as is the potential for vehicle light-weighting. Such components have the potential to contribute to improvements in fuel efficiency and emissions reductions in future passenger vehicle fleets.

► Numerical models of fibre strengthened steel tubes are validated against experiments.
► The frontal crush tubes of two vehicle models are strengthened with carbon fibre.
► The crashworthiness of the vehicles are assessed under frontal collisions.
► Fibre strengthened vehicle components have potential for vehicle light-weighting