Varied thicknesses in the different hat structure regions are expected due to the flow of the polyamide matrix. The results state that with the thermoforming process, arbitrary FMLs material combinations and thicknesses can be processed. To characterize the monomaterials and FMLs, tensile tests at different temperatures and strain rates were performed. Also, finite element analysis using LS-Dyna™ was carried out on the Al-based FMLs to calculate the energy absorption behaviour and analyse the failure modes. Different metallic skin sheets (aluminium and steel) combined with glass fibre reinforced polyamide cores with different fibre orientations and thicknesses were considered. For improved structural integrity, the hat structures were produced using a one-step thermoforming process, in which the forming and bonding of the FMLs layers take place simultaneously. Accordingly, the energy absorption characteristics and failure modes including the arisen microscopic defects are identified. Therefore, this study deals with investigating the structural properties of FMLs top-hat crashboxes under quasi-static and highly-dynamic bending conditions. Recently, the applicability of thermoplastic fibre-metal-laminates (FMLs) in the automotive and aerospace fields has gained more attention due to their lightweight potential and improved flexural stiffness.
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