Adhesively bonded high strength steel axial crush tube investigation

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Joining ultra-high strength steel for vehicle structural components is a challenging application for advanced structural adhesives due to surface coatings and the aggressive loading conditions these materials may encounter in crash scenarios. As designs move towards multi-material vehicle platforms to achieve significant weight reductions, these ultra-high strength steel materials will invariably be joined with other lightweight materials requiring innovative joining methods. High toughness structural adhesives provide a viable option for joining dissimilar materials and addressing significant issues such as corrosion in multi-material assemblies. Of critical importance to the adoption of structural adhesives in vehicle structures is the ability to model or analyze these joints in the vehicle design process. This study will investigate adhesive material characterization and implementation in a finite element code. Physical axial crush tube test samples will be assembled using advanced structural adhesives and tested quasi-statically and dynamically in a crash environment. Numerical models of the structures including the measured adhesive mechanical properties will be used to assess numerical modeling approaches. This research will enable implementation of advanced adhesives in a modeling environment to support the integration and use of adhesives in designs, and to provide near-term solutions for implementation.