Aluminum foams with a functionally graded density have exhibited better impact resistance and a better energy absorbing performance than aluminum foams with a uniform density. Nevertheless, the anisotropic compression behavior caused by the graded density has scarcely been studied. In this paper, a density graded aluminum foam (FG) was prepared by a controlled foaming process. The effect of density anisotropy on the mechanical behavior of FGs was investigated under quasi-static compression and a low-velocity impact. Digital image correlation (DIC) and numerical simulation techniques were used to identify deformation mechanisms at both macro and cell levels. Results show that transverse compression on FGs lead to a higher collapse strength but also to a lower energy absorption, due to the significant decrease in densification strain and plateau stress. The deformation behavior of FGs under longitudinal compression was dominated by the progressive extension of the deformation bands. For FGs under transverse compression, the failure mode of specimens was characterized by multiple randomly distributed deformation bands. Moreover, the transverse compression caused more deformation on cells, through tearing and lateral stretching, because of the high lateral strain level in the specimens. It was concluded that the transverse compression of FGs lead to a lower plateau stress and a lower cell usage, thus resulting in a poorer energy absorption efficient; this constitutes a key factor which should be taken into consideration in structural design.

The main objective of this study is to analyze the impact resistance of aluminum foam composites containing fillers and coatings and to investigate the effect of different thickness ratios of the composites on this capability. We prepared composites using aluminum foam and polyurea and performed impact tests and numerical simulations. A comparison of the results shows that the Abaqus simulation results are in general agreement with the test results. The results show that the polyurea filler material and polyurea coating can significantly improve the impact resistance of the aluminum foam, and the best impact resistance of the aluminum foam composite with polyurea coating on the back. An extended study of the composites was carried out using a numerical model validated by the test results. For the energy absorption effect of the aluminum foam composites in the impact resistance process, there is an optimum value for the thickness ratio of the aluminum foam/polyurea composite, which is 3:1. The remaining kinetic energy of cylindrical fragments in the 3-1-1-2 composite material decreased by 13.26%, in the 4-1-1-2 composite material decreased by 11.91%, in the 2-1-1-2 composite material decreased by 11.78%, and in the 1-1-1-2 composite material increased by 2.7% when compared to the remaining kinetic energy of cylindrical fragments in the control group. The energy absorption efficiency of the aluminum foam composite increases as the residual kinetic energy of the cylindrical fragments decreases. The 3-1-1-2 composite can significantly improve the energy absorption effect, which can be used as a reference for the design of impact-resistant composites in the future.