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Crash and Impact Dynamics of Lightweight Structures
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Crash and Impact Dynamics of Lightweight Structures

Lecture

Lecturer: Prof. Dr.-Ing. Sebastian Heimbs

When: Winter semester, Monday, 13:15 - 14:45 Uhr

Where: HB 35.1 (IFL)

Excercise

Responsible: Prof. Dr.-Ing. Sebastian Heimbs

When: Winter semester, Monday, 15:00 - 15:45

Where: HB 35.1 (IFL)


Crash and impact loads are not a ‘niche’ or special load case, but play a major role in the design of many structures. In automotive vehicle development, front crashes, side crashes and other crash load cases are the decisive drivers for the structural design. In aircraft construction, type certification would not be granted without proof of a crash- and impact-resistant structural design to ensure evacuation after an emergency landing or safe continuation of flight after a bird strike. There are numerous other examples in many other industrial sectors.

Crashtest
Euro NCAP crash test (Credit: Euro NCAP)
Crashsimulation eines Flugzeugrumpfs
Crash simulation of an aircraft fuselage (Credit: Sebastian Heimbs)

Crash- and impact-resistant structural design is a complex and exciting field, as it focuses on highly non-linear material deformation and destruction that requires specialised knowledge of transient dynamic material and damage behaviour as well as physical phenomena in order to develop adequate energy absorbers or robust structures and analyse them in dynamic finite element simulations.

We impart this knowledge and much more in our English-language lecture series ‘Crash and Impact Dynamics of Lightweight Structures’ (3 SWS, 5 ECTS), which is aimed at Master's students in aerospace engineering, automotive engineering, general mechanical engineering or similar fields.

We are delighted to be able to offer students at TU Braunschweig a unique opportunity that is unparalleled anywhere else in the world:

Crushing von Metall- und CFK-Rohren
Crushing of metallic and carbon fibre-reinforced composite tubes (Credit: Sebastian Heimbs)
  • The lecture will be held by two lecturers with decades of industry experience in the field of crash and impact at two leading global corporations, who will provide exciting insights: Prof. Heimbs (formerly Airbus) and guest lecturer Dr. Bergmann (AUDI AG).
  • In addition to theoretical and practical lectures, the focus is on experimental practice in the exercises: Together with the students, we carry out crushing tests on metallic and fibre composite structures as well as impact tests on thin-walled plates at the drop tower in the IFL test hall. In addition to the impressive observation of structural behaviour, we learn important aspects of transient dynamic testing, damage evaluation and data acquisition.
  • Our goal is for students to learn how to model and simulate crash and impact load cases in order to expand their software skills and for possible later application in projects. That is why, in the second half of the semester, we teachhow to set up crash and impact simulations with Abaqus/Explicit in theory and practice in hands-on exercises on the computer.
  • Another exciting highlight is the excursions we offer every year to conduct and experience real full-scale crash and impact tests at leading industrial parter sites and gather unforgettable impressions that will remain in your memory beyond the semester and your studies.
Exkursion im WiSe 24/25: Crashversuch eines PKW mit 115 km/h in einen stehenden PKW
Excursion in WiSe 24/25: Crash test of a car travelling at 115 km/h into a stationary car (Credit: CTS, Crashtest Service GmbH, Münster)
Exkursion im WiSe 24/25: Crashversuch eines PKW mit 115 km/h in einen stehenden PKW
Excursion in WiSe 24/25: Student group photo, CTS, Crashtest Service GmbH, Münster

IFL_CrashImpact_Excursion_2025
Excursion in WiSe 25/26: Crash test of a passenger car traveling at 95 km/h into a stationary tractor (Credit: CTS, Crashtest Service GmbH, Münster)
Exkursion Münster
Excursion in WiSe 25/26: Student group photo, CTS, Crashtest Service GmbH, Münster

The lecture (2 SWS) is divided into the following chapters:

  1. Introduction
  2. Impact Dynamics
  3. Fundamentals of Energy Absorption
  4. Vehicle Crashworthiness: Automotive
  5. Vehicle Crashworthiness: Aircraft
  6. Failure Behaviour under Dynamic Loading
  7. Dynamic Test Methods
  8. Dynamic Crash and Impact Simulations
  9. Dynamic Crash and Impact Simulations: Advanced Topics
  10. Summary & Industry Example

In the exercises (1 SWS), we focus particularly on practical work:

  1. Test and results evaluation: Crushing
  2. Test and results evaluation: Plate impact
  3. FE simulation: Plate impact
  4. FE simulation: Crushing

Lab

Gaskanone des IFL für High-Velocity-Impactversuche
Gas gun of IFL for high-velocity impact tests (Credit: Sebastian Heimbs)

In addition, optional laboratory modules have recently been offered starting in the 2026/27 winter semester, which give students the opportunity — again, unique in the world — to independently conduct bird strike tests as high-velocity impact load cases using state-of-the-art testing and measurement technology. The IFL is the only German university to have a new, modern, large 220 mm caliber gas gun for conducting such tests on site:

 

Small lab: “Crash and Impact Dynamics of Lightweight Structures with Small Lab” (total of 5 SWS / 7 ECTS including lectures/exercises/lab):

The laboratory course (2 SWS) involves the independent preparation, execution, and evaluation of impact tests on the IFL gas gun (bird strike tests using artificial bird projectiles) at increasing impact speeds. As part of the coursework, students must write a structured report summarising and discussing the work steps and results.

Extended (large) lab: „Crash and Impact Dynamics of Lightweight Structures with Lab“ (total of 7 SWS / 11 ECTS including lectures/exercises/lab):

Vogelschlag-Simulation auf eine deformierbare Platte mit Durchschuss
Bird strike simulation on a deformable plate with penetration (Credit: Sebastian Heimbs)

The laboratory course (4 SWS) includes the independent preparation, execution, and evaluation of impact tests on the IFL gas gun (bird strike tests using artificial bird projectiles) at increasing impact speeds, as well as strain rate-dependent material characterization on the new high-rate tensile testing machine. Furthermore, fluid-structure interactions are taught as advanced topics in finite element simulation in order to enable independent simulations of bird strike loading in the commercial FE software Abaqus/Explicit, including the correlation of test and simulation. A graded report and colloquium on the completed lab tests are included in the final grade along with the exam result.

The highest possible quality of teaching is very important to us, which is regularly recognized by students in teaching evaluations and makes this course, “Crash and Impact Dynamics of Lightweight Structures,” a very popular lecture. Here are the results of the teaching evaluations from the last few semesters:

Winter semester 2024/2025: Total score of 4,9 / 5

Winter semester 2025/2026: Total score of 4,9 / 5

Language

  • Lecture: English
  • Lecture slides and documents: English

Exam

  • Written exam: 90 minutes
  • For the large laboratory: graded report and colloquium, counts for 6/11 of the overall grade (written exam 5/11)
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Contact

Institute of Aircraft Design and Lightweight Structures
Hermann-Blenk-Straße 35 
38108 Braunschweig
E-Mail: ifl(at)tu-braunschweig.de
Telephone: +49 531 391 9903

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