Crashworthiness of AAG joints with a foam aluminum layer gusset plate

Abstract

The gusset joint is the most widely used joint system in an aluminum alloy single-layer reticulated shell structure; it plays a vital role in the spatial grid structure. In this paper, the effects of different thicknesses of aluminum alloy gusset plates on the dynamic response and failure modes of aluminum alloy gusset (AAG) joints were studied by impact tests of three specimens. The test results show that the failure modes of AAG joints are a slight depression of the gusset plate, the local buckling of members, the local distortional buckling of members, and tearing of the lower flange and a web of members. The AAG joint inclines along the direction of the failed member and collapses. The finite element model of the AAG joint was established using ANSYS software. The stress, displacement, and deformation modes in the test and numerical simulation results were compared and analyzed, and the rationality of the numerical simulation results was verified. Based on the failure mode of the specimens, a design method for improving the impact resistance of AAG joints with aluminum foam layer gusset plate (AFLGP) is proposed. The numerical simulation results show that an AAG joint with an AFLGP effectively reduces the maximum peak value of impact loads through the deformation of the aluminum foam. In the elastic and elastic-plastic stages, AAG joint with AFLGP had better impact resistance, and the energy absorbed by its rods was 25.44% ∼ 30.36% lower than that of AAG joints alone. Finally, the influence of the thickness of the AFLGP on the impact force and energy absorption of the AAG joint was studied. The aluminum foam gusset layer plate is approximately twice as thick as the aluminum alloy gusset plate had the best protection effect on the AAG joint.