Lighter and better crash safety from energy absorbing 3D-reinforced composite materials

Important results from the project

Various fibre reinforcements have been investigated in composite beams that have been tested both statically and dynamically to compare their energy absorption under extreme loads. Glass and carbon fibre reinforced composite materials are extremely strong but also relatively brittle when they fail. This brittleness can be used for high energy absorption in compression but is not advantageous in bending. Using new 3-dimensional textile techniques, structural toughness of composite beams has been shown that resembles the behaviour of metals that deform plastically.

Expected long term effects

Different composite beams have been experimentally compared by means of energy absorption under static and dynamic loads. Different results were obtained for different types of reinforcement, most of which were produced with new 3-dimensional textile production technology. The results provide guidance for further studies, applications for new larger projects and further efforts to further develop new commercially viable solutions with the help of world-unique Swedish innovations.

Approach and implementation

Beam reinforcements containing glass and carbon fibres were produced by Biteam. These were then resin injected into finished composite beams at KTH, where also half of the beams were tested statically under bending load. The other half of the beams were dynamically tested at Volvo´s crash center. The results were finally compiled and analyzed jointly by KTH, Volvo and Chalmers. The intention is now to proceed with further development of the new material concepts.