Based on the advantages of thin-walled tubes and lattice structures in energy absorption and improved crashworthiness, a hybrid structure of lattice-reinforced thin-walled tubes with different cross-sectional cell numbers and gradient densities was constructed, and a high crashworthiness absorber with adjustable energy absorption was proposed. The experimental and finite element characterization of the impact resistance of uniform density and gradient density hybrid tubes with different lattice arrangements to withstand axial compression was carried out to investigate the interaction mechanism between the lattice packing and the metal shell, and the energy absorption of the hybrid structure was increased by 43.40% relative to the sum of its individual components. The effect of transverse cell number configuration and gradient configuration on the impact resistance of the hybrid structure was investigated, and the results showed that the hybrid structure showed higher energy absorption than the empty tube, and the best specific energy absorption was increased by 83.02%; the transverse cell number configuration had a greater effect on the specific energy absorption of the hybrid structure with uniform density, and the maximum specific energy absorption of the hybrid structure with different configurations was increased by 48.21%. The gradient density configuration had a significant effect on the peak crushing force of the gradient structure. In addition, the effects of wall thickness, density and gradient configuration on energy absorption were quantitatively analyzed. This study provides a new idea to optimize the impact resistance of lattice-structure-filled thin-walled square tube hybrid structures under compressive loading through a combination of experiments and numerical simulations.

In this paper, a new hybrid structure of body-centered cubic lattice-filled thin-walled tube is designed, and the hybrid structure specimens of one-piece printing and split-printing are prepared by laser melting technique. The deformation mode and energy absorption characteristics of the new hybrid structure are investigated by experiments and numerical simulations. Under axial compression, the one-piece printed hybrid structure forms more wrinkles with smaller wavelengths, and the specific energy absorption increases by 12.14% compared with the split-printed structure; under transverse compression, the one-piece printed structure does not show the separation of the thin-walled tube from the lattice, and the specific energy absorption increases by 134.83% compared with the split-printed structure. It is worth noting that the designed hybrid structure has a 112.60% (580.15%) increase in specific energy absorption under axial compression (under transverse compression) compared to the empty tube. The effects of wall thickness, lattice density, and loading rate on the crashworthiness of the hybrid structure were investigated using a validated finite element model. This paper provides a new idea for the preparation of lightweight and high-strength energy-absorbing structures.

The composite sandwich panel of aluminum foam and epoxy resin uses epoxy resin and aluminum foam interpenetration to form a composite surface layer, which makes the surface layer and core material a whole and greatly improves the integrity of the sandwich panel. In this paper, the failure modes of the sandwich panel is studied by drop weight impact tests and compared with traditional sandwich panel. The effects of impact velocity, composite layer thickness and hammerhead shape on the dynamic impact property of the composite sandwich panel are analyzed. The force–time curves, force–displacement curves and energy–time curves were obtained, and the maximum impact force and impact duration time of each group are compared. The results show that the composite sandwich panel exhibits good stability, integrity and energy absorption capability under the impact load. The hammerhead shape has great effect on failure modes and maximum force, and the impact velocity has great effect on the impact duration time. The maximum impact force is affected by composite layer thickness. However, all the factors have little effect on energy absorption capability but greatly affected the growth rate of energy absorption.

The damage process and failure mechanisms were analyzed by a series of quasi-static compressive experiments of seven materials including pure epoxy (EP), three different PPI (pores per linear inch) foam nickel-iron, and three different PPI foam nickel/iron-epoxy interpenetrating phase composites (IPC). Plotting the stress–strain curves of different materials, their change rules are discussed, then the effective elastic modulus and yield limit of the materials are provided, and the energy absorption properties of different materials are analyzed by the stress–strain curves. It was found that the effective elastic modulus and specific stiffness of the three IPC materials were higher than pure foam nickel-iron. The brittleness of epoxy can be obviously changed by selecting a suitable PPI foam nickel-iron composited with it. The unit volume energy absorption rate of foam nickel/iron-epoxy was significantly higher than pure epoxy and pure foam nickel-iron. It was also found that the energy absorption rate decreased with the increase in PPI. The stress relaxation rate decreased first and then increased with the increase in PPI. The creep behavior of the three composites was obvious in the creep elastic stage, and the creep rate increased with the increase in PPI. The creep rate decreased with the increase in PPI in the creep transition stage.

Interpenetrating phase composites (IPCs) are a new type of materials with designable mechanical properties. In this work, to explore a simple, applicable, and accurate method for property designability of interpenetrated phase composites, the interaction between the matrix phase and the reinforcing phase of IPC under compressive stress is discussed, and a microstructured representative volume element is proposed for interpenetrating metal/polymer composites under compressive loading by considering the interaction of constituent phases. The stress–strain relationship of the representative volume element is established based on the iso-stress and iso-strain assumptions. Compared with the experimental results with those of interpenetrated metal/polymer composites, interpenetrated metal/metal composites, and interpenetrated metal/ceramic composites, it is shown that the analytical solutions can accurately predict the elasto-plastic compressive stress–strain curves.

Foam metal/epoxy interpenetrating phase composite is a new type of composite material with interpenetrating continuity in composition, which exhibits different intrinsic relationships under different stress states in tension and compression, and it is necessary to study the intrinsic relationships in the tensile state in depth. A mesoscopic damage-based tensile intrinsic model is developed, and the elasto-plastic tensile intrinsic equations of the representative volume element are derived based on small deformation theory and total strain theory, as well as the assumptions of equal stress and equal strain. The tensile strengths of nickel–iron foam/epoxy interpenetrated phase composites in three different sizes and their constituent phases were measured, and it was shown in the results that the composite of three-dimensional network interpenetration with high-strength foam metal and epoxy resin formed a weak surface inside the material, and did not significantly improve the tensile strength of the composites. The tensile instantonal equations and damage instantonal equations of nickel–iron foam/epoxy interpenetrated phase composites were predicted by the method of inversion, and the applicability and high accuracy of the tensile intrinsic model were verified in comparison with the measured results.