Enhancing Impact Energy Absorption, Flexural and Crash Performance Properties of Automotive Composite Laminates by Adjusting the Stacking Sequences Layup

Alshahrani, Hassan; Ahmed, Azzam

doi:10.3390/polym13193404

Cited by 9 publications

(6 citation statements)

References 46 publications

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“…The damage modes were characterized by combinations of fiber breakage, matrix cracking, fiber/matrix debonding, surface buckling, fiber pull‐out, and delamination. These failure signs were confirmed by Alshahrani and Ahmed 75 . Glass/epoxy composite pipes filled with 3 wt% of Al 2 O 3 shows low matrix fretting, low matrix micro‐cracking and/or low fiber pullout.…”

Section: Resultsmentioning

confidence: 64%

Development of efficient energy absorption components for crashworthiness applications: An experimental study

Alshahrani

Sebaey

Hegazy

et al. 2022

Polymers for Advanced Techs

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This work experimentally investigates the quasi‐static crush response and energy absorption of glass‐reinforced epoxy thin‐walled crash box filled with nano‐aluminum oxide (Al2O3). The effect of the triggering (45 ° edge chamfering) and the weight percentage (wt%) of Al2O3 on the crushing performance have been studied. Field emission scanning electron microscope (FE‐SEM) and energy‐dispersive X‐ray spectroscopy (EDX) were adapted to show the elemental composition of the fabricated samples' surfaces. To follow the fracture mechanism, visual inspection, and scanning electron microscope (SEM) were performed. Two‐parameter Weibull distribution function was employed to statistically analyze the experimental results. Failure probability curves were established to help the designers in selecting the suitable material for energy‐absorbing applications. Results indicated that for untriggered glass/epoxy composite crash boxes, the inclusion of 1, 2, and 3 wt% of nano‐Al2O3 leads to an increase of, respectively, 16.34%, 48.46%, and 68.70% in the absorbed energy (U). While there is a decrease of 32.72% in (U) when adding 4 wt% of nano‐Al2O3. An enrichment of 9.00%, 18.04%, 31.53%, and 11.30% in crush force efficiency (CFE) was reached by the inclusion of, respectively, 1, 2, 3, and 4 wt% of nano‐Al2O3. Triggering has a considerable effect on the crashworthiness parameters of the fabricated composite crash boxes. A decrease of 6.56%, 10.11%, 4.01%, 4.76%, and 11.62% in the initial peak load (Pitalicip), an enrichment of 34.10%, 26.06%, 26.77%, 18.08%, and 28.97% in (CFE) and an improvement of 36.43%, 31.32%, 29.27%, 12.99%, and 52.47% in (U) were reported for composite crash boxes filled with 0, 1, 2, 3, and 4 wt% of nano‐Al2O3. It is obvious that glass/epoxy triggered composite crash boxes filled with 3 wt% of nano‐Al2O3 are appropriate to be used as energy absorbing device employed in vehicles due to their enhanced energy absorbing capabilities.

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Section: Resultsmentioning

confidence: 64%

Development of efficient energy absorption components for crashworthiness applications: An experimental study

Alshahrani

Sebaey

Hegazy

et al. 2022

Polymers for Advanced Techs

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“…The impact energy obtained in the present investigation from the 3D printed composites is comparable to the traditionally made composite structures. In the previous studies related to the impact energy absorption of the traditionally made composites, impact energy of 1.5–3 J (Quaresimin et al , 2013), 5–25 J (Alshahrani and Ahmed, 2021) and 13–21 J (Belingardi and Vadori, 2003) for carbon-epoxy composites and 41–47 J (Belingardi and Vadori, 2002) for glass-epoxy composites have been observed. However, in all these investigations, the thickness of the final specimen is limited to around 2–2.5 mm.…”

Section: Resultsmentioning

confidence: 96%

Impact energy absorption and fracture mechanism of FFF made fiberglass reinforced polymer composites

Prajapati

Dave

Raval

2022

RPJ

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Purpose The fiber reinforced polymer composites are becoming more critical because of their exceptional mechanical properties and lightweight structures. Fused filament fabrication (FFF) is a three-dimensional (3D) printing technique that can manufacture composite structures. However, the effect of impact performance on the structural integrity of FFF made composites compared to the pre-preg composites is a primary concern for the practical usage of 3D printed parts. Therefore, this paper aims to investigate the effect of different processing parameters on the impact performance of 3D printed composites. Design/methodology/approach This paper investigates the impact of build orientation, fiber stacking sequence and fiber angle on the impact properties. Two build orientations, three fiber stacking sequences and two different fiber angles have been selected for this study. Charpy impact testing is carried out to investigate the impact energy absorption of the parts. Onyx as a matrix material and two different types of fibers, that is, fiberglass and high strength high temperature (HSHT) fiberglass as reinforcements, are used for the fabrication. Findings Results indicate that build orientation and fiber angle largely affect the impact performance of composite parts. The composite part built with XYZ orientation, 0º/90º fiber angle and B type fiber stacking sequence resulted into maximum impact energy. However, comparing both types of fiber reinforcement, HSHT fiberglass resulted in higher impact energy than regular fiberglass. Originality/value This study evaluates the damage modes during the impact testing of the 3D printed composite parts. The impact energy absorbed by the composite samples during the impact testing is measured to compare the effect of different processing conditions. The investigation of different types of fiberglass reinforced with Onyx material is very limited for the FFF-based process. The results also provide a database to select the different parameters to obtain the required impact properties.

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“…), the best configuration was given by [(0°/90°) T /0°n/(0°/90°) T ], where (0°/90°) T denotes a fabric reinforcement. Alshahrani et al [155] stated that the highest energy of unidirectional C/E laminates made by the compression molding process was absorbed by the sequence [(0°/90°/45°/−45°) 2 /0°/90°] S . When using C/E tubes, generally, it emerged that longitudinally oriented fibres have less influence on crashworthiness performance compared to hoop (90°)-oriented ones [124,130], due to the dominant folding failure mechanism.…”

Section: Stacking Sequencementioning

confidence: 99%

Natural Fibre and Hybrid Composite Thin-Walled Structures for Automotive Crashworthiness: A Review

Capretti,

Del Bianco,

Giammaria

et al. 2024

Materials

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Natural fibres, valued for their low density, cost-effectiveness, high strength-to-weight ratio, and efficient energy absorption, are increasingly emerging as alternatives to synthetic materials in green composites. Although they cannot fully replace synthetic counterparts, like carbon, in structural applications due to their inferior mechanical performance, combining them through hybridization presents a potential solution. This approach promotes a balance between environmental benefits and mechanical efficiency. Recently, the transportation sector has shifted its focus towards delivering lightweight and crashworthy composite structures to improve vehicle performance, address safety concerns, and minimise environmental impact through the use of eco-friendly materials. The crashworthiness of energy absorbers, typically thin-walled structures, is influenced by several factors, including their material and geometric design. This paper presents a comprehensive overview of recent studies focused on the crashworthiness of fibre-reinforced, thin-walled composites under axial crushing. It explores different aspects, such as their materials, cross-sections, stacking sequences, triggering or filling mechanisms, and the effect of loading rate speed. Emphasis is placed on natural-fibre-based materials, including a comparative analysis of synthetic ones and their hybridization. The primary objective is to review the progress of solutions using green composites as energy absorbers in the automotive industry, considering their lightweight design, crashworthiness, and environmental sustainability.

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Enhancing Impact Energy Absorption, Flexural and Crash Performance Properties of Automotive Composite Laminates by Adjusting the Stacking Sequences Layup

Cited by 9 publications

References 46 publications

Development of efficient energy absorption components for crashworthiness applications: An experimental study

Development of efficient energy absorption components for crashworthiness applications: An experimental study

Impact energy absorption and fracture mechanism of FFF made fiberglass reinforced polymer composites

Natural Fibre and Hybrid Composite Thin-Walled Structures for Automotive Crashworthiness: A Review

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