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Sarah Shoffner

Guardians of the Cockpit: The Life-saving Role of Halos and Aeroscreens


 

In the high-stakes world of motorsport, where speeds exceed 200 mph, and the slightest mistake can lead to disaster, driver safety is paramount. Since the tragic crash of Jules Bianchi at the 2014 Japanese Grand Prix, significant strides have been made in enhancing the safety of drivers. Introducing the Halo in Formula 1 and the Aeroscreen in IndyCar are two of the most critical advancements. Initially met with skepticism and controversy, these devices have proven their worth by saving lives and reducing the severity of injuries in numerous high-speed crashes, underscoring their crucial role in enhancing driver safety.


Photo via XPBimages

The Birth of the Halo

The FIA (Fédération Internationale de l’Automobile) played a crucial role in the development and implementation of the Halo. They began investigating frontal protection devices in 2011, exploring options such as full canopies and rollbar-like structures. By 2015, the Halo emerged as the most promising solution after rigorous testing.

The introduction of the Halo in 2018 was met with mixed reactions. Some team principals and drivers were concerned about its impact on visibility and the aesthetics of the cars. However, the turning point came with Charles Leclerc’s 2018 Belgian Grand Prix incident. Fernando Alonso’s McLaren was launched over Leclerc’s Sauber, and the Halo protected Leclerc’s head from a potentially fatal blow. This incident, along with others, gradually shifted the perspective of skeptics.


Engineering Marvel: The Halo

Contrary to popular belief, the Halo is not made entirely of carbon fiber but from a titanium alloy known as Grade 5 6AL4V. This aerospace-grade material allows the Halo to weigh only 7kg while withstanding immense forces. The structure is designed to endure 15 times the static load of a Formula 1 car and can deflect a 20kg wheel traveling at 225 kph.

Manufacturing the Halo involves precise engineering and stringent quality control. The process starts with gun drilling and turning the outer diameter of titanium bars. These bars are then bent using a method called ‘cold bending’ to avoid oxidation. The tubes are welded using a bespoke shroud technique to ensure high-quality welds without oxidation. The final assembly is machined to precise tolerances to ensure a perfect fit with the chassis.


Testing the Halo

Each Halo must pass rigorous safety tests to become ‘FIA-approved.’ These tests, conducted at the Cranfield Impact Centre, involve applying significant vertical, frontal, and lateral loads. The Halo must withstand these forces without any failure in the structure or attachment to the survival cell. The Halo’s ability to protect drivers has been validated in numerous real-world crashes, demonstrating its effectiveness in enhancing driver safety.


The Aeroscreen: IndyCar’s Answer

While Formula 1 adopted the Halo, IndyCar introduced the Aeroscreen, developed by Red Bull Advanced Technologies in collaboration with PPG. The Aeroscreen combines a laminated polycarbonate windscreen with a titanium frame to protect drivers from debris and impacts. The windscreen is designed to withstand debris flying at velocities exceeding 220mph, withstanding strikes from objects such as a 10kg tire and wheel assembly.

PPG, a leader in aerospace transparencies, utilized its expertise in designing the windscreen. The laminated construction, similar to that used in aircraft canopies, provides superior impact resistance. The windscreen features an anti-ice system adapted from aircraft technology to prevent fog and condensation. The complex shape and attachment methods required custom manufacturing processes to ensure the windscreen’s strength and reliability.


Photo via Andy Hone / Motorsport Images

Transformative Incidents

The effectiveness of the Halo and Aeroscreen has been demonstrated in several high-profile incidents. Romain Grosjean’s fiery crash at the 2020 Bahrain Grand Prix is one of the most notable. Grosjean’s car split in two upon impact with a barrier, and the Halo deflected the barrier, creating a protective zone around his head. Grosjean escaped with minor injuries, a testament to the Halo’s life-saving capabilities.


Another significant incident was the collision between Lewis Hamilton and Max Verstappen at the 2021 Italian Grand Prix. Verstappen’s car landed on top of Hamilton’s, and the Halo protected Hamilton’s head from the impact of Verstappen’s rear wheel. This incident further cemented the Halo’s role in driver safety.


Drivers who have experienced crashes with and without the Halo or Aeroscreen can provide a firsthand account of the safety benefits. Their perspectives can be particularly impactful in changing the perspectives of the audience. In IndyCar, the Aeroscreen has also proven its worth. During the 2020 season, it protected drivers from debris and impacts in numerous crashes. The Aeroscreen’s ability to withstand high-velocity impacts and provide clear visibility has made it an essential safety device in the series.


Changing Perspectives

When the Halo and Aeroscreen were first introduced, they faced significant resistance from team principals, drivers, and fans. Concerns ranged from aesthetics and visibility to potential aerodynamic disadvantages. However, the life-saving incidents involving these devices have silenced many critics.


Former McLaren team principal Ron Dennis was initially skeptical about the Halo, citing concerns about visibility and the car’s aesthetics. However, after witnessing its effectiveness, he strongly advocated the device. Similarly, Red Bull Racing’s Christian Horner once doubted its necessity but acknowledged its importance after the device saved Charles Leclerc at the Belgian Grand Prix.


Photo via Chris Jones / IndyCar

IndyCar team owners and drivers have expressed similar sentiments. Roger Penske, a prominent figure in the series, initially had reservations about the Aeroscreen’s impact on car performance. However, after seeing the device in action, he praised its role in enhancing driver safety. Drivers like Scott Dixon and Will Power have also lauded the Aeroscreen for providing an additional layer of protection without compromising visibility.


Conclusion

The Halo and Aeroscreen represent a new era in motorsport safety. Their innovative designs, rigorous testing, and proven effectiveness have made them indispensable components in Formula 1 and IndyCar. While initial skepticism and controversy surrounded their introduction, the life-saving incidents involving these devices have changed the perspectives of team principals, drivers, and fans alike.


As motorsport continues to push the boundaries of speed and performance, the Halo and Aeroscreen stand as guardians of the cockpit, ensuring that drivers can compete with greater peace of mind. These devices are a testament to the relentless pursuit of safety in motorsport, proving that technology and innovation can save lives and protect the heroes of the racetrack.


Edited by Carla Martínez






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