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<p>Lightweight energy-absorbing structures with enhanced crashworthiness are of critical importance in transportation and protective engineering applications, where improved crush resistance and weight efficiency are essential for ensuring structural safety. In this context, the present study investigates the crashworthiness performance of glass fiber-reinforced epoxy (GFRE) composite tubes filled with nanoaluminum-modified polyurethane (PU) foam under quasi-static lateral conditions. GFRE tubes were fabricated using the hand layup method with strict control of geometry and mass to ensure consistent specimen characteristics. PU foam was enhanced by incorporating nanoaluminum particles at 2, 4, and 6 wt.%, and the modified foam was subsequently used to fill the GFRE tubes. Quasi-static compression tests were conducted while continuously recording load–displacement responses and monitoring progressive failure mechanisms. Key crashworthiness metrics, including total energy absorption (<i>U</i>), average crushing load (<i>Fₘ</i>), and specific energy absorption (SEA), were evaluated to quantitatively evaluate the energy-dissipation performance of each configuration. The experimental results reveal that both foam filling and the nano-Al content significantly contribute to improving the crashworthiness performance of GFRE tubes. Between the tested designs, tubes filled with 4&#xa0;wt.% nano-Al-enhanced foam (FF4%) displayed the most favorable overall performance, achieving a <i>U</i> of 76.54 J, a Fₘ of 0.79&#xa0;kN, and a SEA of 1.56&#xa0;J/g. In contrast, further growing the nano-Al content to 6&#xa0;wt.% resulted in a reduction in these crashworthiness indicators, suggesting the existence of an optimal nano-Al concentration beyond which the beneficial effects diminish.</p>

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Structural Efficiency Enhancement of GFRE Composite Tubes through Nano-Aluminum-Reinforced Foam under Lateral Compression

  • 期刊论文

  • 发表日期：

    2026年4月6日

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  • Mahmoud M. Awd Allah,
  • Mahmoud F. Abd El-Halim,
  • Mohamed Ibrahim Abd El Aal,
  • Marwa A. Abd El-baky

摘要

Lightweight energy-absorbing structures with enhanced crashworthiness are of critical importance in transportation and protective engineering applications, where improved crush resistance and weight efficiency are essential for ensuring structural safety. In this context, the present study investigates the crashworthiness performance of glass fiber-reinforced epoxy (GFRE) composite tubes filled with nanoaluminum-modified polyurethane (PU) foam under quasi-static lateral conditions. GFRE tubes were fabricated using the hand layup method with strict control of geometry and mass to ensure consistent specimen characteristics. PU foam was enhanced by incorporating nanoaluminum particles at 2, 4, and 6 wt.%, and the modified foam was subsequently used to fill the GFRE tubes. Quasi-static compression tests were conducted while continuously recording load–displacement responses and monitoring progressive failure mechanisms. Key crashworthiness metrics, including total energy absorption (U), average crushing load (Fₘ), and specific energy absorption (SEA), were evaluated to quantitatively evaluate the energy-dissipation performance of each configuration. The experimental results reveal that both foam filling and the nano-Al content significantly contribute to improving the crashworthiness performance of GFRE tubes. Between the tested designs, tubes filled with 4 wt.% nano-Al-enhanced foam (FF4%) displayed the most favorable overall performance, achieving a U of 76.54 J, a Fₘ of 0.79 kN, and a SEA of 1.56 J/g. In contrast, further growing the nano-Al content to 6 wt.% resulted in a reduction in these crashworthiness indicators, suggesting the existence of an optimal nano-Al concentration beyond which the beneficial effects diminish.