Abstract
Aluminium honeycomb, renowned for its energy-absorption capabilities, poses significant manufacturing challenges. To address adhesive failure and premature collapse in traditional aluminium honeycomb, this study presents a novel approach - friction stir welded aluminium honeycomb. Traditional honeycombs can lose up to 50 % of their strength during low-velocity impacts, underscoring the need to comprehend the crashworthiness and crushing behaviour of this innovative solution. The study employs a robust finite element framework to predict crashworthiness parameters and deformation under flatwise compression. Enhanced with damage criterion, it offers more realistic predictions, indicating no debonding in welded regions. Most energy is dissipated through plastic folding, making it suitable for high-energy absorption applications. Damage initiates at the corner of the flanges due to stress concentration, minimized by a design modification to barrel-shaped honeycomb, boosting crushing strength by 21 %. This study aids in predicting responses of friction stir welded aluminium honeycombs for design optimization.
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