Designed metal-polymer-metal sandwich structures for improved energy absorption characteristics of crash structures

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Currently, developing robust modelling and calculation methods describing the deformation and failure behaviour of structural components made of multi-layered hybrid materials subjected to crash loading conditions is still a major challenge. In the case of metal-polymer-metal (MPM) layered composites, this difficulty is primarily attributed to the time-dependent mechanical behaviour of the polymeric core and the metallic cover layers as well as the unexpected behaviour of the metal/polymer interface under such highly dynamic loading conditions. In addition, the relevant properties used for the material model are significantly affected by the manufacturing process conditions.The current project aims at developing predictive modelling approaches of the crash behaviour of variably configurable MPM layered composites. In this regard, reliable methodologies aiming at the adjustment of tailored energy absorption characteristics will be developed. On the one hand, an increase of the structural energy absorption is targeted, and on the other hand the deformation behaviour will be selectively adjusted by means of local failure mechanisms. For this purpose, methods and design guidelines are to be established enabling an efficient adjustment of adequate and locally-variable MPM layered composites properties in combination with adapted process routines for crash-loaded structural components. Moreover, multi-scale modelling and characterisation strategies considering the processing history will be applied. In this regard, experimental investigations under different loading rates and conditions are foreseen to establish the material model.