Crash-worthiness Analysis of Hollow Hybrid Structural Tube by Aluminum with Basalt-Bamboo Hybrid Fiber Laminates by Roll Wrapping Method

Hollow hybrid structural tubes were evaluated using commercial-grade Diamond Micro Expanded Mesh (DMEM) thin mesh of aluminum (Al) as structural reinforcement. Axial, transverse (flexural), and radial compression tests were performed on four different layered hybrid structures using bamboo (Bm) and basalt (B). With a maximum force of 34.7 kN, compressive ultimate strength of 238 MPa, and strain of 12.6%, AlBmB (with layers labeled from inside to outside) was the best performer in the axial compression test. AlBmB’s adaptability was demonstrated by the flexural test, showing a maximum bending force of 4.7 kN, a flexural strength of 97.7 MPa, and a decreased deflection of 13.2 mm. Radial compression test results underscored the superior energy absorption characteristics of AlBmB. The varying material interfaces in the hybrid tubes yielded distinctive performances. AlBmB, incorporating bamboo and basalt layers, stood out with superior energy absorption and crush force characteristics, indicating enhanced crashworthiness. The other hybrids AlBm, AlB, and BmB also exhibited commendable performances, emphasizing the adaptability of different material combinations. The meticulous selection of DMEM and innovative roll wrapping method for fabrication reliably influenced the tubes’ mechanical properties. The study contributes to advancing the design of lightweight, durable, and high-strength components.