Relationship between service life heat exposure and extruded aluminum structural crashworthiness has been conducted. This research, part of a broader program, consists of investigating five aluminum alloy extrusions each of which is subjected to two heat treatments. The aluminum extrusion investigated are 6063T6, 6061T6, 6260T6, 6014T6, and 7129T6. The two heat treatments are 177°C for 30 minutes and 200°C for 24 hours. The 200°C/24 hours treatment represents the most severe thermal exposure i.e. components adjacent to exhaust pipes and manifolds. The 200°C heat treatment is in addition to the 177°C for 30 minutes. All specimens were subjected to the reference 177°C for 30 minutes treatment. These ten crash members were subjected to static axial crushing at a speed of 25.4 mm/minute (1 in/min). Force-time data was collected and responses were plotted for all tests. Force-displacement responses were integrated for the crush energy management and mean axial crush load for each of the aluminum extruded crash members. Bar charts were then generated to describe the crush loads and energy management behaviors of the various aluminum alloys and associated heat treatments. Severe service life simulated heat exposure was found to affect the mean crush load and crush energy management of the aluminum structural crush members. The heat exposure effects on the crashworthiness of the extruded aluminum members ranged from a reduction of 8% to over 20% in the mean crush load and crush energy management with highest variation observed with the 6260T6 aluminum extrusion.

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