In the pursuit of global energy conservation and emissions reductions, utilizing beverage cans as energy-absorbing components offers potential for a sustainable economy. This study examines the impact of foam filling on the crushing behaviors and energy absorption of various types of beverage cans. Quasi-static compression tests were conducted on five geometrically sized cans filled with three densities of polyurethane foam to study their deformation modes and calculate crashworthiness parameters within the effective stroke. Results show that empty beverage cans have lower energy absorption capacities, and deformation modes become less consistent as can size increases. Higher foam density leads to increased total energy absorption, a slight reduction in the effective compression stroke, and a tendency for specific energy absorption to initially increase and then decrease. Regarding crush behavior, smaller cans transition from a diamond mode to a concertina mode, while larger cans exhibit a columnar bending mode. Next, the coupling effect of energy absorption between foam and cans was analyzed so as to reveal the design method of energy-absorbing components. The specific energy absorption of smaller cans filled with polyurethane foam is superior to that of similar empty cans. These findings provide valuable insights for selecting next-generation sustainable energy absorption structures.

Creating lightweight and impact-resistant box structures has been an enduring pursuit among researchers. A new energy-absorbing structure consisting of a bionic gradient lattice-enhanced thin-walled tube is presented in this article. The gradient lattice and thin-walled tube were prepared using selective laser melting (SLM) and wire-cutting techniques, respectively. To analyze the effects of gradient pattern, mass ratio, diameter range and impact speed on structural crashworthiness, low-speed impact at 4 m/s and finite element simulation experiments were conducted. The study demonstrates that the design of inward radial gradient lattice-reinforced thin-walled tubes can effectively enhance structure\'s energy-absorption efficiency and provide a more stable mode of deformation. It also shows a 17.44% specific energy-absorption advantage over the uniformly lattice-reinforced thin-walled tubes, with no significant overall gain in peak crushing force. A complex scale evaluation method was used to determine the optimum structure and the structure type with the best crashworthiness was found to be a gradient lattice-filled tube with a thickness of 0.9 mm and a slope index of 10. The gradient lattice-reinforced thin-walled tube suggested in this investigation offers guidance for designing a more efficient thin-walled energy-absorption structure.

Based on the advantages of thin-walled tubes and lattice structures in energy absorption and improved crashworthiness, a hybrid structure of lattice-reinforced thin-walled tubes with different cross-sectional cell numbers and gradient densities was constructed, and a high crashworthiness absorber with adjustable energy absorption was proposed. The experimental and finite element characterization of the impact resistance of uniform density and gradient density hybrid tubes with different lattice arrangements to withstand axial compression was carried out to investigate the interaction mechanism between the lattice packing and the metal shell, and the energy absorption of the hybrid structure was increased by 43.40% relative to the sum of its individual components. The effect of transverse cell number configuration and gradient configuration on the impact resistance of the hybrid structure was investigated, and the results showed that the hybrid structure showed higher energy absorption than the empty tube, and the best specific energy absorption was increased by 83.02%; the transverse cell number configuration had a greater effect on the specific energy absorption of the hybrid structure with uniform density, and the maximum specific energy absorption of the hybrid structure with different configurations was increased by 48.21%. The gradient density configuration had a significant effect on the peak crushing force of the gradient structure. In addition, the effects of wall thickness, density and gradient configuration on energy absorption were quantitatively analyzed. This study provides a new idea to optimize the impact resistance of lattice-structure-filled thin-walled square tube hybrid structures under compressive loading through a combination of experiments and numerical simulations.

A crashworthiness design of foam-filled local nanocrystallized thin-walled tubes (FLNTs) is proposed by using foam-filled structures and ultrasonic impact surface treatment. The crashworthiness and deformation modes of FLNTs are studied using an experiment and numerical analysis. A finite element numerical model of FLNTs is established, and the processing and test platform of FLNTs is set up to verify the numerical predication and analytical design. The results show that local nanocrystallization is an effective method to enhance crashworthiness for hexagonal FLNTs. The FLNTs with four circumferential continuous stripes of surface nanocrystallization exhibit a level of 47.12% higher specific energy absorption than the untreated tubes in numerical simulations for tubes with a 50% ratio of nanocrystallized area. Inspired by the strength mechanism, a novel nested foam-filled local surface nanocrystallization tube is further designed and studied in detail.

Thin-walled structures are commonly used as energy absorbers in motor vehicles. Their function is to protect the structural components of vehicles and to absorb energy completely during collisions up to 20 km/h. This paper focuses on maintaining crush axiality during research. To verify the numerical analyses, physical specimens were made and then subjected to dynamic crushing. Force and shortening values as well as high-speed camera images were used for data analysis. Through time-lapse shots, plastic deformation within the crush initiator was observed. Such detailed analysis allowed the determination of the influence of hexagonal triggers in the form of notches on the post-buckling progressive analysis. In this paper, neural networks were used to examine the importance of each variable. Data from numerical analyses were used for this purpose. Based on the analyses performed, the effects of both the width and height of the triggers on the crush load efficiency (CLE) and total efficiency (TE) ratios can be seen. The width of the crush initiator has the greatest influence on Crash-box performance. Nevertheless, increasing both the height and the width of the initiator can result in crush non-axiality and underperformance of the energy absorber.

Recent polymer and metal additive manufacturing technologies were proven capable of building complex structures with high accuracy. Although their final products differ significantly in terms of mechanical properties and building cost, many structural optimization studies were performed with either one without systematic justification. Therefore, this study investigated whether the Direct Metal Laser Sintering (DMLS) and Fused Deposition Modelling (FDM) methodologies can provide similar conclusions when performing geometrical manipulations for optimizing structural crashworthiness. Two identical sets of four shapes of stiffened hexagonal cells were built and crushed under quasi-static loading. The results were compared in terms of collapsing behavior, load-carrying performance, and energy-absorption capability. Although the observed failure modes were different since the base-materials differ, similar improvement trends in performance were observed between both fabrication approaches. Therefore, FDM was recommended as a fabrication method to optimize thin-walled cellular hexagonal parameters since it was 80% more time-efficient and 53.6% cheaper than the DMLS technique.

To provide an objective basis on which to evaluate the repeatability of vehicle crash test methods, a recently developed signal analysis method was used to evaluate correlation of sensor time history data between replicate vehicle crash tests. The goal of this study was to evaluate the repeatability of rollover crash tests performed with the Dynamic Rollover Test System (DRoTS) relative to other vehicle crash test methods.
Test data from DRoTS tests, deceleration rollover sled (DRS) tests, frontal crash tests, frontal offset crash tests, small overlap crash tests, small overlap impact (SOI) crash tests, and oblique crash tests were obtained from the literature and publicly available databases (the NHTSA vehicle database and the Insurance Institute for Highway Safety TechData) to examine crash test repeatability.
Signal analysis of the DRoTS tests showed that force and deformation time histories had good to excellent repeatability, whereas vehicle kinematics showed only fair repeatability due to the vehicle mounting method for one pair of tests and slightly dissimilar mass properties (2.2%) in a second pair of tests. Relative to the DRS, the DRoTS tests showed very similar or higher levels of repeatability in nearly all vehicle kinematic data signals with the exception of global X\' (road direction of travel) velocity and displacement due to the functionality of the DRoTS fixture. Based on the average overall scoring metric of the dominant acceleration, DRoTS was found to be as repeatable as all other crash tests analyzed. Vertical force measures showed good repeatability and were on par with frontal crash barrier forces. Dynamic deformation measures showed good to excellent repeatability as opposed to poor repeatability seen in SOI and oblique deformation measures.
Using the signal analysis method as outlined in this article, the DRoTS was shown to have the same or better repeatability of crash test methods used in government regulatory and consumer evaluation test protocols.