Driving the future: How FlexCrash is transforming vehicle safety and sustainability

Imagine cruising down the highway, feeling secure in your vehicle, when suddenly, a close call forces you to brake just in time. It’s a powerful reminder of how crucial vehicle safety is in our daily lives. In the evolving automotive industry, traditional crash tests have long been the foundation of automotive safety regulations. But as car designs become more complex and sustainability takes a more central role, how can we maintain safety without excessive costs or environmental impact?

The FlexCrash European project—is working to provide a general improvement in car safety with a reduction of risks and fatalities in crashes. The project promotes a wide usage of the advanced materials and manufacturing solutions to build a new generation of crash-tolerant structures with outstanding performance under a wide range of impact angles and unexpected crash conditions.

Traditional crash tests have long been the benchmark for assessing vehicle safety. However, they are often expensive and resource-intensive. With the automotive landscape evolving rapidly, a shift is needed. This is where virtual crash testing comes into play. Aerobase Innovations AB contributes by developing more accurate and adaptable safety simulations that replicate real-world scenarios. By moving away from expensive, full-scale physical tests, Aerobase not only enhances vehicle safety but also ensures optimal resource use, contributing to a more sustainable future.

When it comes to safety, every detail counts, especially at the microscopic level. Using more recycled material creates challenges. Elements with high melting temperature like Cu becomes concentrated in Aluminium that is recycled multiple times and is one source to variations in mechanical properties, especially the strain at failure. One of Aerobase’s exciting advances involves creating a specialized model that considers the variations in grain size present in High-Pressure Die Cast (HPDC) components. Why is this significant? The mechanical properties of these materials can change dramatically from the surface to the core, depending on their grain structure. By factoring in these intricate details, Aerobase is improving the accuracy and realism of crash simulations.

Moreover, Aerobase uses micro-CT scanning technology and mechanical testing, to analyze the critical flaws in HPDC components. These small imperfections can significantly impact a vehicle’s resilience in a crash. The data collected from these scans is then used to develop probabilistic models that predict how and when a component might fail, creating safer designs from the ground up.

When combined with a crash simulation, probabilistic material models can predict not only whether a failure will occur but also how and when it might happen (Figure 1). This approach enables engineers to evaluate failure scenarios under different loading conditions. This approach helps them assess the risks associated with their design choices, allowing for adjustments to materials and designs that optimize performance and improve crashworthiness while minimizing unnecessary material use. Figure 1 shows the force-displacement response when the risk of failure D_crit of the material is varied. The interpretation of D_{crit. =} 50% is that half of the manufactured components will be crack free up to this point.

Figure 1. Prediction of force displacement response and crack initiation in an aluminium HPDC component during axial compression load.

One of the primary goals of the project is to develop advanced virtual testing environments that make physical crash tests on large structures increasingly rare. Within FlexCrash, Aerobase is working tirelessly to craft a future where safety, efficiency, and sustainability go hand in hand. However, as we advance, we also face essential ethical considerations. How can we ensure that virtual tests genuinely reflect real-world conditions? Who is responsible for protecting the vast amounts of data generated? These are not just technical questions but also ethical ones that require careful consideration and discussion.

Aerobase’s contributions to the FlexCrash project exemplify how innovation and collaboration can transform our approach to vehicle safety. By harnessing the power of advanced material modeling and cutting-edge technology, we are not only shaping the future of crash testing but also steering us toward a safer and greener tomorrow. So, the next time you hit the road, remember that the safety features keeping you secure may have originated not in traditional crash labs but through powerful simulations. Welcome to the new era of automotive safety—where safety meets sustainability on every drive.