Abstract This paper presents an integrated approach for an ultimate high-performance safety toe cap with significant milestones in slim design and weight saving. The study of crashworthiness properties was performed through impact-crash test conditions exploring the potential of applicant solutions by the combination of an advanced high-strength steel and enhanced geometric stiffening models. The structural response for a significant thickness reduction was assessed and it provides an evolved discussion for improvements in energy absorption capacity. The present case study focuses on two geometric models from the S3 slim toe cap development by prototypes made of a martensitic 1200 steel alloy. The comparison of results is complemented using numerical simulation models with mathematical description of the dynamic plasticity behaviour by applying a constitutive Cowper-Symonds equation with fundamental parameters for material strain-rate dependence.

This study presents experimental results on the behaviour of aluminium alloy metal structures and foams manufactured by lost-wax casting and using 3D printed components for internal structure definition. Results for tensile tests, metallurgical properties, surface quality and geometry tolerances were obtained and discussed. The analysis focused on development geometries, used for adjusting manufacturing parameters and prototype geometries intended for geometrical and mechanical validation. The results are indicative of the viability of the method for producing foam structures suitable for mechanical loading.

This study presents an approach for the improvement of crashworthiness properties of aluminium tubular structures using initiators introduced through localized heating. The main objective of this approach is to improve the ability to absorb impact energy in a progressive and controlled manner by a local modification of material properties. Through a localized heating in areas previously chosen for initiation, associated with the softening of the aluminium alloy the deformation can be introduced precisely, forcing the tubular structure to deform in a mode of high energy absorption and reducing the maximum load in a controlled manner. This study presents the properties for an aluminium alloy 6061-T5 modified by thermal treatment by the use of a laser beam. Experimental results are presented of quasi-static and impact tests of tubular structures using the proposed approach. This concept appears as possible and effective in the experimental work presented.

This paper presents results on the tensile testing of AZ31B-H24 magnesium alloy and 6111-T4 aluminium alloy at different strain rates. These materials are strong candidates for use in crashworthy automotive components and parts due to their well-balanced combination of strength, stiffness and density. To test their application in the auto industry an understanding of material behaviour at relevant strain rates is needed, as well as constitutive equations suitable for use in analytical and numerical calculations. Mechanical properties were determined from tensile tests using flat sheet samples, employing two different test techniques: a servo-hydraulic machine and a tensile-loading Hopkinson bar. The test results were used to compare different mechanical properties of the tested materials and to validate constitutive equations intended to provide a mathematical description of strain rate dependence. The Cowper-Symonds equation was examined.