Effect of the Combination of Ultra-High-Molecular-Weight Polyethylene, Denim Fabric, and Aluminum on the Functional...

Vehicle crash boxes are elements that protect the integrity of vehicles and ensure the safety of occupants in potential vehicle accidents. These crash boxes are mounted on the chassis of vehicles. In this study, composite crash boxes fabricated from aluminum, which is known for its lightweight properties, as well as denim and ultra-high-molecular-weight polyethylene, both of which are widely available on the market, were investigated experimentally. Composite crash boxes composed of an epoxy resin matrix reinforced with denim fabric (DenimFRP) and ultra-high-molecular-weight polyethylene (UHMWPEFRP) fibers, as well as aluminum (Al), were produced. The crash boxes were manufactured using a vacuum infusion method. This combination was produced by wrapping these fibers around an aluminum core. The energy absorption values, peak force values, and specific energy absorption values of the manufactured crash boxes were obtained through quasi-static compression tests and then compared. The best energy absorption value was achieved with the Al+denimFRP composite crash box manufactured by wrapping denim around aluminum at a workload of 1645.22 J, and its specific energy absorption value was also calculated as 15.52 J/g. The difference between the highest and lowest energy absorption was determined to be 244.61%. The highest peak strength value was obtained with the Al+denim+UHMWPEFRP sample, which contained a combination of aluminum on the inside, denim fabric in the middle, and UHMWPE fabric on the outside. Among the individually produced samples, the Al+denimFRP composite crash box manufactured with denim fiber exhibited higher results compared with the UHMWPEFRP composite box manufactured with ultra-high-molecular-weight polyethylene.