SpringerLink
Log in

Hybrid Metal/Composite Structures Under Quasi-static Axial Compression Loads: A Comparative Study

  • Regular Article
  • Published:
Fibers and Polymers Aims and scope Submit manuscript

Abstract

This research presents an experimental examination of the crashworthiness performance and the crush history of hybrid constructions made of metal and composite materials. The metallic part is aluminum alloy (Al6063), while the composite part is carbon (C) and E-glass (G) textiles reinforced with epoxy. The hand lay-up technique of wet wrap** was used to fabricate the specimens, which were then tested under quasi-static axial compression pressure. Two groups of hybrid structures were fabricated: the first group is glass fiber reinforced epoxy (GFRE) overwrapped Al6063 tubes, whereas the second group is the hybridization between carbon fiber reinforced epoxy (CFRE) and GFRE-overwrapped Al6063 tubes. A number of crashworthiness indicators were evaluated for the suggested tubes, including the initial peak force (Fip), total absorbed energy (AE), mean crush force (Fm), specific absorbed energy (SEA), and crush force efficiency (CFE). The experimental results exhibited that for group one, the Al6063/8G tube has the maximum Fip, Fm, AE, and CFE with values of 77.54 kN, 47.87 kN, 3350.99 J, and 0.62, respectively, while the Al6063 tube shows the maximum SEA with a value of 44.63 J/g. Furthermore, the Al6063/4G/4C tube in group two displays values of, respectively, 120.44 kN, 81.56 kN, 5709.41 J, 59.74 J/g, and 0.68 the extreme for Fip, Fm, AE, SEA, and CFE.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Price includes VAT (France)

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7

Similar content being viewed by others

Data Availability

Upon reasonable request, the corresponding author can supply the datasets generated and/or analyzed during the current work.

References

  1. S. Ming, Z. Song, C. Zhou, K. Du, C. Teng, Y. Wang, S. Xu, B. Wang, The crashworthiness design of metal/CFRP hybrid tubes based on origami-ending approach: Experimental research. Compos. Struct. 279, 114843–114858 (2022)

    Article  Google Scholar 

  2. M.M. Awd Allah, A. Shaker, M.A. Hassan, M.A. Abd El-baky, The influence of induced holes on crashworthy ability of glass reinforced epoxy square tubes. Polym. Compos. 43(11), 8322–8340 (2022)

    Article  CAS  Google Scholar 

  3. M.A.A. El-Baky, M.M.A. Allah, M. Kamel, W. Abd-Elaziem, Lightweight cost-effective hybrid materials for energy absorption applications. Sci. Rep. 12(1), 21101 (2022)

    Article  CAS  PubMed  PubMed Central  Google Scholar 

  4. M.M.A. Allah, M.A.A. El-baky, A.A. Mousa, D.A. Hegazy, How do silicon carbide nanoparticles affect the crashworthiness performance of glass/epoxy composite tubes? Fibers Polym. 25(2), 651–660 (2023)

    Article  Google Scholar 

  5. Y. Wang, M. Lou, Y. Wang, C. Fan, C. Tian, X. Qi, Experimental investigation of the effect of rotation rate and current speed on the dynamic response of riserless rotating drill string. Ocean Eng. 280, 114542 (2023)

    Article  Google Scholar 

  6. M.A. Attia, M.A. Abd El-Baky, M.A. Hassan, T.A. Sebaey, E. Mahdi, Crashworthiness characteristics of carbon-jute-glass reinforced epoxy composite circular tubes. Polym. Compos. 39(S4), E2245–E2261 (2018)

    Article  CAS  Google Scholar 

  7. M.M. Awd Allah, M.A. Abd El-baky, M.A. Hassan, A. Shaker, Crashworthiness performance of thin-walled glass/epoxy square tubes with circular cutouts: an experimental study. Fibers Polym. 23(11), 3268–3281 (2022)

    Article  CAS  Google Scholar 

  8. M.A.A. El-Baky, M.M.A. Allah, M. Kamel, W. Abd-Elaziem, Energy absorption characteristics of E-glass/epoxy over-wrapped aluminum pipes with induced holes: an experimental research. Sci. Rep. 12(1), 21097 (2022)

    Article  CAS  PubMed  PubMed Central  Google Scholar 

  9. C. Zhang, H. Khorshidi, E. Najafi, M. Ghasemi, Fresh, mechanical and microstructural properties of alkali-activated composites incorporating nanomaterials: a comprehensive review. J. Clean. Prod. 384, 135390 (2023)

    Article  CAS  Google Scholar 

  10. Y.-Y. Wang, M. Lou, Y. Wang, W.-G. Wu, F. Yang, Stochastic failure analysis of reinforced thermoplastic pipes under axial loading and internal pressure. China Ocean Eng. 36(4), 614–628 (2022)

    Article  Google Scholar 

  11. M.A. Abd El-Baky, A.E. Alshorbagy, A.M. Alsaeedy, M. Megahed, Fabrication of cost effective fiber metal laminates based on jute and glass fabrics for enhanced mechanical properties. J. Nat. Fibers 19(1), 303–318 (2020)

    Article  Google Scholar 

  12. H. Guo, J. Zhang, Expansion of sandwich tubes with metal foam core under axial compression. J. Appl. Mech. 90(5), 051008 (2023)

    Article  CAS  Google Scholar 

  13. K.C. Shin, J.J. Lee, K.H. Kim, M.C. Song, J.S. Huh, Axial crush and bending collapse of an aluminum/GFRP hybrid square tube and its energy absorption capability. Compos. Struct. 57(1–4), 279–287 (2002)

    Article  Google Scholar 

  14. M.A.A. El-baky, M.M.A. Allah, M. Kamel, W. Abdel-Aziem, Fabrication of glass/jute hybrid composite over wrapped aluminum cylinders: an advanced material for automotive applications. Fibers Polym. 24(1), 143–155 (2023)

    Article  Google Scholar 

  15. J. Xu, Y. Zhang, Y. Huang, L. Chang, T. Chen, T. Ren, Z. Cai, Dynamic response of chain mail fabrics with variable stiffness. Int. J. Mech. Sci. 264, 108840 (2024)

    Article  Google Scholar 

  16. J.M. Babbage, P.K. Mallick, Static axial crush performance of unfilled and foam-filled aluminum–composite hybrid tubes. Compos. Struct. 70(2), 177–184 (2005)

    Article  Google Scholar 

  17. R. Kalhor, S.W. Case, The effect of FRP thickness on energy absorption of metal-FRP square tubes subjected to axial compressive loading. Compos. Struct. 130, 44–50 (2015)

    Article  Google Scholar 

  18. Q. Liu, Z. Mo, Y. Wu, J. Ma, G.C. Pong Tsui, D. Hui, Crush response of CFRP square tube filled with aluminum honeycomb. Compos. Part B Eng. 98, 406–414 (2016)

    Article  CAS  Google Scholar 

  19. Q. Liu, X. Xu, J. Ma, J. Wang, Y. Shi, D. Hui, Lateral crushing and bending responses of CFRP square tube filled with aluminum honeycomb. Compos. B Eng. 118, 104–115 (2017)

    Article  CAS  Google Scholar 

  20. G. Zhu, G. Sun, Q. Liu, G. Li, Q. Li, On crushing characteristics of different configurations of metal-composites hybrid tubes. Compos. Struct. 175, 58–69 (2017)

    Article  Google Scholar 

  21. D., Chen, G. Zhu, X. Huo, X. Liu, and G. Sun. Quasi-static crushing of different configurations of metal-composites hybrid tubes under axial/lateral loading. In 21st International Conference on Composite Materials. 2017.

  22. G. Sun, S. Li, G. Li, Q. Li, On crashing behaviors of aluminium/CFRP tubes subjected to axial and oblique loading: An experimental study. Compos. B Eng. 145, 47–56 (2018)

    Article  CAS  Google Scholar 

  23. Z. Wang, X. **, Q. Li, G. Sun, On crashworthiness design of hybrid metal-composite structures. Int. J. Mech. Sci. 171, 7740–7753 (2020)

    Article  Google Scholar 

  24. M. Zang, Y. Hu, J. Zhang, W. Ye, M. Zhao, Crashworthiness of CFRP/aluminum alloy hybrid tubes under quasi-static axial crushing. J. Mark. Res. 9(4), 7740–7753 (2020)

    CAS  Google Scholar 

  25. M.M.A. Allah, D.A. Hegazy, H. Alshahrani, T.A. Sebaey, M.A.A. El-baky, Fiber metal laminates based on natural/synthesis fiber composite for vehicles industry: an experimental comparative study. Fibers Polym. 24(8), 2877–2889 (2023)

    Article  CAS  Google Scholar 

  26. M. Megahed, M.A. Abd El-baky, A.M. Alsaeedy, A.E. Alshorbagy, An experimental investigation on the effect of incorporation of different nanofillers on the mechanical characterization of fiber metal laminate. Compos. Part B Eng. 176, 107277–107289 (2019)

    Article  CAS  Google Scholar 

  27. M.M. Awd Allah, M.A. Abd El-baky, H. Alshahrani, T.A. Sebaey, D.A. Hegazy, Multi attribute decision making through COPRAS on tensile properties of hybrid fiber metal laminate sandwich structures for aerospace and automotive industries. J. Compos. Mater. 57(24), 3757–3773 (2023)

    Article  Google Scholar 

  28. M. Megahed, M.A. Abd El-baky, A.M. Alsaeedy, A.E. Alshorbagy, Synthesis effect of nano-fillers on the damage resistance of GLARE. Fibers Polym. 22(5), 1366–1377 (2021)

    Article  CAS  Google Scholar 

  29. H. Alshahrani, T.A. Sebaey, M.M. Awd Allah, M.A. Abd El-baky, Jute-basalt reinforced epoxy hybrid composites for lightweight structural automotive applications. J. Compos. Mater. 57(7), 1315–1330 (2023)

    Article  CAS  Google Scholar 

  30. M. M. Awd Allah, D. A. Hegazy, H. Alshahrani, T. A. Sebaey, M. A. Abd El-baky, Exploring the effect of nanoclay addition on energy absorption capability of laterally loaded glass/epoxy composite tubes. Polym. Composit. (2023). https://doi.org/10.1002/pc.27572

    Article  Google Scholar 

  31. D. A. Hegazy, M. M. Awd Allah, H. A. Alshahrani, T. Sebaey, M. A. Abd El-Baky, Lateral crashing response of thin-walled composite structures filled with carbon nanopowder. Polym. Composit. (2023). https://doi.org/10.1002/pc.27702

    Article  Google Scholar 

  32. M.M. Awd Allah, M.A. Abd El-baky, H. Alshahrani, T.A. Sebaey, D.A. Hegazy, Energy absorption capability of laterally loaded glass/epoxy tubular components containing halloysite nanotubes. J. Compos. Mater. 57, 00219983231204976 (2023)

    Article  Google Scholar 

  33. X. Zhao, G. Zhu, C. Zhou, Q. Yu, Crashworthiness analysis and design of composite tapered tubes under multiple load cases. Compos. Struct. 222, 110920–110935 (2019)

    Article  Google Scholar 

  34. N. Gan, Y. Feng, H. Yin, G. Wen, D. Wang, X. Huang, Quasi-static axial crushing experiment study of foam-filled CFRP and aluminum alloy thin-walled structures. Compos. Struct. 157, 303–319 (2016)

    Article  Google Scholar 

  35. M.A. Guler, M.E. Cerit, B. Bayram, B. Gerçeker, E. Karakaya, The effect of geometrical parameters on the energy absorption characteristics of thin-walled structures under axial impact loading. Int. J. Crashworthiness 15(4), 377–390 (2010)

    Article  Google Scholar 

  36. M.M.A. Allah, M.A.A. El-baky, H. Alshahrani, T.A. Sebaey, M. Kamel, Crashworthiness of hybrid pipes with triggering mechanism under quasi-static axial compression. Fibers Polym. 24(12), 4397–4411 (2023)

    Article  Google Scholar 

  37. H. Alshahrani, T.A. Sebaey, M.M. Awd Allah, M.A. Abd El-baky, Metal/polymer composite cylinders for crash energy absorption applications. Polym. Compos. 43(12), 8771–8783 (2022)

    Article  CAS  Google Scholar 

  38. E.F. Abdewi, S. Sulaiman, A.M.S. Hamouda, E. Mahdi, Quasi-static axial and lateral crushing of radial corrugated composite tubes. Thin-Walled Structures 46(3), 320–332 (2008)

    Article  Google Scholar 

  39. H. Alshahrani, T.A. Sebaey, M.M. Awd Allah, M.A. Abd El-baky, Multi-response optimization of crashworthy performance of perforated thin walled tubes. J. Compos. Mater. 57(9), 1579–1597 (2023)

    Article  Google Scholar 

  40. M. Mirzaei, M. Shakeri, M. Sadighi, H. Akbarshahi, Experimental and analytical assessment of axial crushing of circular hybrid tubes under quasi-static load. Compos. Struct. 94(6), 1959–1966 (2012)

    Article  Google Scholar 

  41. M.I.A. El Aal, M.M. Awd Allah, M.A. Abd El-baky, Carbon-glass reinforced epoxy hybrid composites for crashworthy structural applications. Polym. Compos. 44(5), 2910–2924 (2023)

    Article  Google Scholar 

  42. J. Rouzegar, H. Assaee, S.M. Elahi, H. Asiaei, Axial crushing of perforated metal and composite-metal tubes. J. Brazilian Soc. Mech. Sci. Eng. 40(7), 1–16 (2018)

    Article  Google Scholar 

  43. D.A. Hegazy, M.M. Awd Allah, H. Alshahrani, T.A. Sebaey, and M.A. Abd El‐baky, Effect of alumina nano‐particles on collapse behavior and energy absorption of laterally loaded glass/epoxy composite tubes. Polym. Compos

  44. M.M.A. Allah, D.A. Hegazy, H. Alshahrani, T.A. Sebaey, M.A.A. El-baky, Crush analysis of hybrid glass/nano-silica/epoxy composite cylinders under lateral loading conditions. Fibers Polym. 25(1), 289–299 (2023)

    Article  Google Scholar 

  45. M.M. Awd Allah, W. Abdel-Aziem, M.A. Abd El-baky, Collapse behavior and energy absorbing characteristics of 3D-printed tubes with different infill pattern structures: an experimental study. Fibers Polym. 24, 2609 (2023)

    Article  Google Scholar 

  46. B. **a, X. Huang, L. Chang, R. Zhang, Z. Liao, Z. Cai, The arrangement patterns optimization of 3D honeycomb and 3D re-entrant honeycomb structures for energy absorption. Mater. Today Commun. 35, 105996 (2023)

    Article  CAS  Google Scholar 

  47. M.I. Abd El Aal, M.M. Awd Allah, S.A. Abd Alaziz, A. El-baky, A. Marwa, Biodegradable 3D printed polylactic acid structures for different engineering applications: effect of infill pattern and density. J. Polym. Res. 31(1), 1–15 (2024)

    Article  Google Scholar 

  48. H. Alshahrani, T.A. Sebaey, M.M. Awd Allah, M.A. Abd El-baky, Quasi-static axial crushing performance of thin-walled tubes with circular hole discontinuities. J. Compos. Mater. 56(27), 4195–4218 (2022)

    Article  CAS  Google Scholar 

  49. W. Zhang, S. Kang, X. Liu, B. Lin, Y. Huang, Experimental study of a composite beam externally bonded with a carbon fiber-reinforced plastic plate. J. Build. Eng. 71, 106522 (2023)

    Article  Google Scholar 

Download references

Acknowledgements

This study is supported via funding from Prince Sattam bin Abdulaziz University project number (PSAU/2024/R/1445).

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Southern Methodist University, Dallas, 75201, USA

    Mahmoud M. Awd Allah

  2. Department of Mechanical Design and Production Engineering, Zagazig University, Zagazig, 44519, Egypt

    Mahmoud M. Awd Allah & Marwa A. Abd El-baky

  3. Department of Mechanical Engineering, College of Engineering at Wadi Alddawasir, Prince Sattam Bin Abdulaziz University, Wadi Addawasir, 18734, Saudi Arabia

    Mohamed I. Abd El Aal

  4. Industrial Engineering Department, College of Engineering, King Khalid University, Abha, 61421, Saudi Arabia

    Marwa A. Abd El-baky

  5. Center for Engineering and Technology Innovations, King Khalid University, Abha, 61421, Saudi Arabia

    Marwa A. Abd El-baky

Authors
  1. Mahmoud M. Awd Allah
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Mohamed I. Abd El Aal
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Marwa A. Abd El-baky
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Mohamed I. Abd El Aal.

Ethics declarations

Conflict of interest

The authors did not reveal any potential conflicts of interest.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Allah, M.M.A., El Aal, M.I.A. & El-baky, M.A.A. Hybrid Metal/Composite Structures Under Quasi-static Axial Compression Loads: A Comparative Study. Fibers Polym 25, 1403–1415 (2024). https://doi.org/10.1007/s12221-024-00513-8

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12221-024-00513-8

Keywords

Search

Navigation