Lightweight Energy Absorbing Aluminium Structures (LEAAST)

A new generation of aluminium alloys and casting techniques will be tested in crash management systems for cars and trains, aiming to replace the steel parts currently used in bumpers and rail crash structures. This matters because steel is heavy. Automotive manufacturers like Jaguar Land Rover already use aluminium for car bodies but still rely on steel for bumper beams. Rail crash systems are almost entirely steel-based. The project combines two advances: Constellium’s stronger AA6xxx aluminium alloys, which are fully recyclable alongside standard automotive sheet aluminium, and Brunel University’s casting technologies that allow extrusions and castings to be joined in novel ways. The team will use overcasting techniques, bonded joints, and riveted joints to combine a high-strength alloy with casting alloys. If successful, the project could produce lighter, more compact crash management systems that maintain or improve crash resistance. For everyday life, this means safer vehicles that weigh less, improving fuel efficiency or battery range without compromising passenger protection. For rail transport, lighter crash structures could reduce overall train weight, cutting energy use across the network. The work is applied engineering with a clear practical goal: demonstrate and evaluate optimised designs for both automotive and rail applications.