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The document D2.3 “Advanced lab-scale testing for crashworthiness estimation of hybrid specimens” collects the work performed by the Flexcrash consortium in Task 2.3 and is related to Key Exploitable Results (KER) 9 and 10.

Deliverable D2.3 details the lab-scale testing performed by the Flexcrash consortium to evaluate the crashworthiness of aluminium structures reinforced with Added Value Functional Features (AVFFs), produced via Directed Energy Deposition with Laser Beam and Powder (DED-LB/P) additive manufacturing. The objective was to validate the mechanical performance of these reinforcements under realistic loading conditions and support further development of crash-tolerant automotive components.

Testing focused on three main areas: fracture toughness, fatigue resistance, and high-speed crash performance. AVFFs showed similar fracture behaviour to the base aluminium alloy, although specimen limitations affected the precision of toughness measurements. A novel, efficient fatigue testing method was introduced, revealing that while AVFFs increased stiffness, they did not significantly improve fatigue life due to crack initiation at the reinforcement. High-speed axial crash tests demonstrated that reinforced crash boxes absorbed energy comparably to unreinforced ones, with no cracking but some weld delamination. 3-point bending tests highlighted that AVFFs notably improved energy absorption under compression (up to 75%) but had limited benefit under tensile loading due to early brittle fracture. Heat treatments improved ductility and energy absorption under compression.
Overall, AVFFs enhance structural performance under specific conditions, particularly compressive stress. These results guide further optimization of reinforcement design for industrial application in lightweight, crash-resistant structures.


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