Compressive response and energy absorption of foam-filled aluminum honeycomb composite: experiments and simulation

In this study, the effect of foam-filling pattern on the compressive response and energy absorption capacity of the aluminum honeycomb composite has been investigated. An aluminum honeycomb core and a polyurethane foam were used to produce foam-filled honeycomb panels in three patterns with the same volume fraction of the foam. Experimental quasi-static compression tests were performed in the in-plane direction. Numerical analysis based on the conducted tests was also performed by ABAQUS finite element software in similar laboratory conditions to verify the accuracy of the experiments. The results show that the polyurethane-filling pattern is effective in the compressive behavior of the honeycomb core due to the creation and change of the shear bands, the length of the path deflection, and compressive force distribution. At an angle of 30 degrees-35 degrees, the honeycomb materials deform in the in-plane direction, forming shear bands with a greater strain. However, by using the optimized foam pattern-alternating pattern-in addition to enhancing the honeycomb's compressive strength and energy absorption capacity by 490% and 800%, respectively, the foam usage rate can be reduced up to 35% compared to the full foam mode, resulting in lower cost.