Crashworthiness Performance Evaluation of Thin-Walled Tubes Filled with Single and Hybrid-Lattice Structures Under Axial Impact Loading Using Finite Element Analysis

Year 2025, Volume: 9 Issue: 3, 284 - 293, 30.09.2025

Mahmoud Sultan , Anwar Kandil Mohamed Baraya

https://doi.org/10.30939/ijastech..1711179

Abstract

This study aims to evaluate the crashworthiness performance of hybrid energy-absorbing structures composed of thin-walled square tubes filled with various lattice configurations. The research seeks to determine how combining different lattice types (single, dual-hybrid, and tri-ple-hybrid) affects energy absorption under axial impact loading, contributing to the develop-ment of lightweight and high-performance crashworthy systems for transportation safety. Finite Element Analysis (FEA) was performed using Abaqus/Explicit to simulate axial impact loading on hybrid models. Each model consisted of a thin-walled square aluminum tube (Al6063-T5) filled with an internal lattice structure (AlSi10Mg). Lattice configurations included single (BCC, FCC, Cubic), dual-hybrid (Cubic+BCC, Cubic+FCC, BCC+FCC), and triple-hybrid (Cu-bic+BCC+FCC) combinations. To ensure a fair comparison, the total mass of all models was fixed at 27.0 g (19.78 g tube + 7.22 g lattice) by adjusting lattice strut diameters accordingly. Crashworthiness metrics (Total Energy Absorption (EA), Specific Energy Absorption (ES), Peak Crushing Force (FP), Mean Crushing Force (FM), and Crushing Force Efficiency (ηF)) were computed. Validation against published experimental data confirmed the accuracy of the FEA methodology, with a deviation percentage below 3.5%. Generally, the dual-hybrid and triple-hybrid models showed enhanced crashworthiness performance compared to single-hybrid models. The triple-hybrid model demonstrated the best crashworthiness performance with an EA of 1024.009 J and an ES of 37.926 J/g. This represents a 13.5% improvement over the top dual-hybrid model and a 17.1% improvement over the best single-hybrid model. The combi-nation of multiple lattice structures within hybrid energy absorbers significantly improves crashworthiness performance. The findings support the integration of complex lattice architectures in lightweight energy-absorbing components for enhanced safety in transportation applications.

Keywords

Lattice Structures , Crashworthiness Performance , Energy Absorption , Crash Box , Thin-Walled Tubes , Abaqus/Explicit , Finite Element Analysis (FEA)

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