Comparative analysis of the use of classic and light materials in the construction of energy-absorbing structures in vehicles

This study investigates the performance of steel and aluminum alloys in the construction of energy-absorbing elements used in front collision management systems, essential for enhancing vehicle safety during frontal impacts. These systems are designed to absorb and dissipate impact energy while minimizing the acceleration forces transmitted to vehicle occupants, which could lead to injury. The research evaluates the impact of material choice and geometric modifications on the performance of these absorbers, using FEM. Steel absorbers, known for their high strength, effectively absorb energy through plastic deformation while maintaining structural integrity. On the other hand, aluminum absorbers, with their lower density, offer notable advantages in reducing the overall mass of the vehicle, thus improving fuel efficiency and performance. However, a comprehensive analysis of the current state of knowledge on these materials in energy absorption applications is necessary. Previous studies, such as those by Bhardawaj et al.[201] and Hussain et al. [192], have explored similar aspects using simulation techniques, providing a foundation for further development in this field. Additionally, material properties and their impact on structural performance have been examined, offering insights into lightweight design optimization [3]. This study also explores two geometric modifications—perforations and indentations—designed to optimize the absorber's acceleration profile and enhance energy dissipation. While these modifications have been analyzed in prior research, their combined impact with material selection in crash absorbers remains insufficiently examined. Therefore, this work builds on existing findings to further investigate the effectiveness of these geometric features, integrating insights from recent studies. The results provide valuable insights into how material selection and geometric optimization can be combined to lightweight and high-performing energy-absorbing elements in collision management systems. Additionally, this study highlights gaps in the literature and suggests future directions for optimizing energy dissipation in crash absorbers, ensuring a well-grounded contribution to the state of knowledge.