SALIENT has achieved the following results:
1. A comprehensive set of new crash scenarios defining key impact parameters (speed, angle, energy, geometry), and identification of SAV and AV traffic penetration rates and roll-out strategies to better predict future accidents.
2. A new Base Crashworthiness FES (BCFES) design with improved multi-angle crashworthiness, and three promising Adaptive Crashworthiness FES (ACFES) concepts:
• AC1FES: Adaptable material stiffness using smart materials/SMAs.
• AC2FES: Controlled crash load paths.
• AC3FES: Inflatable/pressurized structural elements.
The BCFES achieved about 52% weight reduction vs baseline and can be transferred to the Body in White (BiW), enabling lighter and safer vehicle structures. The AC1 crash-box improved frontal crash compatibility, delayed deformation, reduced peak loads, mitigated firewall intrusion, and smoothed acceleration profiles.
3. Development of three lightweight, recyclable, multi-functional materials for the FES: 6063 Al alloy, CFPA6-tape, and hybrid Al/TP-CFRP based on local reinforcement with unidirectional CF tapes. These materials support circularity principles. The CFPA6-tape hybrid can be thermally dissolved and recycled for new components. The single-alloy 6063 design allows about 95% material recovery without property loss.
4. Optimized forming and production technologies for TP-CFRPs and hybrid materials achieving high production rates with >25% energy savings, >20% faster production, 10% cost savings, and <5% waste. The new tool geometry and surface improved line speed and cost-efficiency, producing 5 UD-tapes per line, directly enhancing sustainability and productivity.
5. A novel ADAS sensing algorithm capable of detecting and communicating the details of imminent crashes, coupled with a triggering mechanism (TrM) to activate ACFES systems based on pre-crash signals.
6. An innovative MSE simulation platform providing >10% higher correlation between tests and simulations, >30% broader assessment scope, and >20% higher efficiency in solving simulations. CAE-test correlation reached ≥80% at component level, supporting a full crash analysis for future accident types. Multi-SMA virtual layers increased energy absorption by +22.2%, meeting project targets. In oblique impacts (±30°), BCFES and AC1 outperformed baselines; in heavy truck scenarios, AC1 maintained structural integrity and load capacity.
These achievements feed the SALIENT exploitation strategy, initially identifying 24 Key Exploitable Results (KERs). After prioritization, five KERs were developed into detailed exploitation roadmaps covering needs, tasks, revenues, costs, and financing. The EXPLOITT methodology (H2020) guided the process, assessing commercial potential and defining suitable business models. The strategy was further strengthened with input from the Horizon Results Booster.
