Tailored metal-polymer-metal layered composites for improved energy absorption characteristics of crash structures

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The deformation and failure behaviour of crash-relevant structural components made of metal-polymer-metal (MPM) layered composites is strongly dependent of the strain rate-dependent material behaviour of the individual layers and the adhesion behaviour between the layers under highly dynamic loads. In the DFG project "Tailor-made metal-polymer-metal layered composites for improved energy absorption characteristics of crash structures", a strategy for consistent modeling and calculation of hybrid crash boxes made of MPM layer composites was developed and successfully applied. It was shown qualitatively that the adhesion behaviour is essential for the structural one and the resulting energy absorption capacity and can be further increased by a targeted and local adjustment. For this purpose, methods and design guidelines have to be developed that enable an efficient setting of load-related MPM layer composite properties for crash-loaded structural components. In addition, the influence of suitable joining concepts, strain hardening caused by the forming process and induced residual stresses on the crash behaviour of MPM structures has not yet been sufficiently investigated. Based on the established cross-scale modeling and characterization strategy for MPM layer composites, the project foreseen will finally predict the crash behaviour of locally configurable MPM layer composites by considering the forming and joining processes. Based on this, procedures for setting tailor-made energy absorption characteristics will be developed. On the one hand, the structural energy absorption should be increased and, on the other hand, the deformation behaviour should be specifically influenced by means of local failure mechanisms.