In high-pressure dynamic thermodynamic processes, the pressure is much higher than the air critical pressure, and the temperature can deviate significantly from the Boyle temperature. In such situations, the thermo-physical properties and pneumatic performance can’t be described accurately by the ideal gas law. This paper proposes an approach to evaluate the pneumatic performance of a high-pressure air catapult launch system, in which esidual functions are used to compensate the thermal physical property uncertainties of caused by real gas effects. Compared with the Nelson-Obert generalized compressibility charts, the precision of the improved virial equation of state is better than Soave-Redlich-Kwong (S-R-K) and Peng-Robinson (P-R) equations for high pressure air. In this paper, the improved virial equation of state is further used to establish a compressibility factor database which is applied to evaluate real gas effects. The specific residual thermodynamic energy and specific residual enthalpy of the high-pressure air are also derived using the modified corresponding state equation and improved virial equation of state which are truncated to the third virial coefficient. The pneumatic equations are established on the basis of the derived residual functions. The comparison of the numerical results shows that the real gas effects are strong, and the pneumatic performance analysis indicates that the real dynamic thermodynamic process is obviously different from the ideal one.

A high-pressure pneumatic catapult works under extreme boundaries such as high-pressure and rapid change of pressure and temperature, with the features of nonlinearity and gas-solid convection. In the thermodynamics processes, the pressure is much larger than the critical pressure, and the compressibility factor can deviate from the Zeno line significantly. Therefore, the pneumatic performance and thermo-physical properties need to be described with the real gas hypothesis instead of the ideal gas one. It is found that the analytical results based on the ideal gas model overestimate the performance of the catapult, in comparison to the test data. To obtain a theoretical model with dynamic leakage compensation, leakage tests are carried out, and the relationship among the leakage rate, pressure and stroke is fitted. The compressibility factor library of the equation of state for compressed air is established and evaluated by referring it to the Nelson-Obert generalized compressibility charts. Based on the Peng–Robinson equation, a theoretical model of the high-pressure pneumatic catapult is developed, in which the effects of dynamic leakage and the forced convective heat transfer between the gas and the metal wall are taken into account. The results from the theoretical model are consistent with the data from ejection tests. This research presents an approach to study the performance of a high-pressure pneumatic catapult with high precision.

This study systematically investigates the high-velocity impact response and energy absorption characteristics of carbon fiber-reinforced plastic (CFRP)—aluminum foam (AlF) hybrid composite structures, aiming to address the growing demand for lightweight yet high-performance energy-absorbing materials in aerospace and protective engineering applications. Particular emphasis is placed on elucidating the influence of key geometric and material parameters, including the aspect ratio of the columns and the relative density of the AlF core. Experimental characterization was first performed using a split Hopkinson pressure bar (SHPB) apparatus to evaluate the dynamic compressive behavior of AlF specimens with four different relative densities (i.e., 0.163, 0.245, 0.374, and 0.437). A finite element (FE) model was then developed and rigorously validated against the experimental data, demonstrating excellent agreement in terms of deformation modes and force–displacement responses. Extensive parametric studies based on the validated FE framework revealed that the proposed CFRP-AlF composite structure achieves a balance between specific energy absorption (SEA) and peak crushing force, showing a significant improvement over conventional CFRP or AlF. The confinement effect of CFRP enables AlF to undergo progressive collapse along designated orientations, thereby endowing the CFRP-AlF composite structure with superior impact resistance. These findings provide critical insight for the design of next-generation lightweight protective structures subjected to extreme dynamic loading conditions.

This study proposes a novel graded-thickness, thin-walled aluminum alloy (Al) circular tube energy-absorbing structure and conducts comprehensive parametric modeling and multi-objective optimization research. The 7050Al tube was selected for analysis of its energy absorption characteristics via numerical simulations and drop-weight impact tests. Through simulation calculations and drop hammer impact verification tests, the number and location of concertina lobes after crushing, as well as the force variation law of the structure during the crushing process, were analyzed. The results indicate that generating annular folds at the impact end can significantly enhance impact absorption and suppress structural instability. Drop-weight test results further validate the superior crashworthiness of the proposed 7050Al tube under dynamic loading conditions and confirm the accuracy of the numerical crushing model. To enable rapid and precise structural modifications, a Python-based parametric modeling framework has been developed. A fully automated parametric optimization workflow has been established within Isight to facilitate the efficient, multi-objective optimization of the structure’s design. This methodology provides a robust tool for designing customizable energy-absorbing structures with tailored crashworthiness performance.