Crashworthiness performance of pentagonal multi-cell carbon filament/aluminium circular hybrid tube under axial crushing

The main objective of this study was to evaluate the energy absorption capability and impact deformation behavior of an additional reinforcement in a hybrid carbon-filament structure as an optimal impact-resistant configuration. The hybrid tubes were fabricated using aluminum and carbon fiber 3D-printing filaments, with a pentagonal geometry applied to the inner sidewall. Four pentagonal-dimensional models were developed and categorized as Very Small Range (HPVS), Small Range (HPSR), Medium Range (HPMR), and Large Range (HPLR). Quasi-static compression tests were conducted experimentally to characterize the structural behavior of the hybrid tube configurations under quasi-static. The results showed that the HPSR model exhibited the highest energy absorption, reaching 3.522 kJ, followed by HPMR with 3.067 kJ, HPLR with 3.050 kJ, and HPVS with 2.844 kJ. The load-displacement curves revealed a consistent and distinct deformation pattern within the displacement range of 0-65 mm for all models. In contrast, within the displacement range of 65-100 mm, the HPLR and HPVS models exhibited irregular responses, indicating buckling phenomena that compromised structural stability and integrity. Overall, the hybrid pentagonal design offers a well-balanced solution in terms of energy absorption (EA), specific energy absorption (SEA), crush force efficiency (CFE), and peak crushing force (PCF), indicating its strong potential for application in future energy-absorbing structures.

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