INVESTIGATION OF A METALLIC SANDWICH DESIGN WITH THERMOPLASTIC CORE FOR IMPROVED PEDESTRIAN PROTECTION

Abstract

Sandwich structures with PA6 foam as core material were investigated for car applications. For certification, cars have to satisfy certain safety standards required for pedestrian impact scenarios. New solutions are sought for, which offer improved pedestrian protection whilst keeping or reducing the mass of the vehicle. In this study sandwich materials consisting of PA6 foams and aluminium coversheets were analysed. Since the automotive sector is very sensitive to costs, an in-situ joining technique was analysed by directly using the melted thermoplastic material as adhesive. In an experimental study, the performance of the adhesive bonding was characterised. Virtual material descriptions were derived from the sandwich materials by performing quasi-static and dynamic material tests. Finally, impact studies were conducted on the material, testing the performance of the sandwich and validating the numerical models.