Impact Energy Absorption Research Articles

Impact resistance of polyvinyl alcohol-polypropylene fiber toughened foamed concrete under low-velocity impact: experiments and 3D meso-scale modelling

Foamed concrete exhibits good energy absorption and shock absorption properties due to its microporous structure. Compared with conventional concrete, foamed concrete can more readily enter the plastic stage and more effectively reflect and absorb impact energy. However, a scientific deficit of knowledge about the impact resistance of foamed concrete with various hardeners and there is a lack of accurate verified models of such a process. In this study, the impact resistance of polyvinyl alcohol-polypropylene fiber toughened foamed concrete under different impact speeds and different amounts of polyvinyl alcohol has been investigated using the cube drop weight impact test. The toughening mechanism of polyvinyl alcohol is revealed through XRD analysis. In addition, 3D meso-scale modelling of a composite material composed of foam, mortar, an interface transition zone and fiber was conducted using the Python-based secondary development of Abaqus to simulate impact resistance. The results have demonstrated that the impact resistance (ultimate bearing capacity, total absorbed energy and dynamic increase factor) of the toughened foamed concrete samples initially increased and subsequently decreased with the addition of polypropylene fiber and polyvinyl alcohol. At the impact speed of 1.6m/s, compared with ordinary foamed concrete, the ultimate bearing capacity of polyvinyl alcohol polypropylene fiber toughened foamed concrete is increased by 107.8%, the total absorbed energy is increased by 119.7%, and the dynamic increase coefficient is increased by 31.6%; At the impact speed of 2.0m/s, compared with ordinary foamed concrete, the ultimate bearing capacity of polyvinyl alcohol polypropylene fiber toughened foamed concrete is increased by 134.2%, the total absorbed energy is increased by 87.9%, and the dynamic increase coefficient is increased by 50%. The simulation results are in good agreement with the test results, establishing that 3D meso-scale modelling modeling can accurately describe the impact resistance test of foamed concrete. It is further confirmed that 3D meso-scale modelling is reliable for predicting the impact resistance of polymer-fiber toughened foamed concrete.

Investigation of Impact Behaviour of Sisal Fiber Reinforced Phenol Formaldehyde Composites

Short Sisal fiber reinforced Phenol Formaldehyde resin composites are prepared with varied fiber lengths (5 mm and 10 mm) and for varied weight fraction (20%, 25% and 30%) of the fibers. Here in this work, Sisal fiber is used as reinforcement. Since it is abundantly available in nature and majority of it is getting wasted without being used as reinforcement in engineering applications. Over the last thirty years composite materials, plastics and ceramics have been the dominant emerging materials. The 10 mm fiber length reinforced composite shown improved mechanical properties than 5 mm fiber length reinforced composite. Increase in impact strength is seen when the fiber content in the composite is increased from 20% to 25% and 25% to 30%. The fiber strength, for different fiber lengths and fiber volume fraction, the work of fracture is proportional to the fiber length and fiber volume fraction. Although results show increment in impact strength with fiber volume fraction, proportionality is not demonstrated. This suggests that there are other mechanisms that affect the impact strength of the composites. Crack propagation is the predominant toughening mechanism in notched impact test. Improvement in impact strength characterizes that fibers as stress transferring medium are able to absorb impact energy effectively. Good interaction with crack increases the energy needed for further crack formation and propagation. The exceptional case could be due to low fiber content and relatively short fiber length so that the energy is not dissipated effectively. Weak interfacial bonding of natural fibers is mainly due to incompatibility of hydrophobic matrix and hydrophilic fiber. High moisture absorption causes dimensional changes of natural fibers as well.

Recent Experimental Advances in Solid–Liquid Composites for Impact and Blast Mitigation

The development of high-performance composites for mechanical energy dissipation during impact or explosive events is of vital importance for the safety of personnel and infrastructures. Solid–liquid composites are an emerging class of energy absorbers where a liquid-phase filler is seamlessly integrated into a solid matrix to enhance the impact resistance of the protection target. This innovative approach leverages the distinct properties of both phases and the unique interactions between them to achieve superior performance under high-impact conditions. This paper aims to review the liquid-phase materials used in solid–liquid composites, ranging from neat liquids to complex fluids, including liquid nanofoam and shear-thickening fluids, to provide an in-depth analysis of the fundamental physics underpinning the resulting solid–liquid composites, and to explore how their unique properties contribute to enhanced impact resistance and energy absorption. Furthermore, this paper evaluates the advantages and limitations of these solid–liquid composites and offers insights into future directions for the development of solid–liquid composites in various fields, including personal protective equipment, automotive safety systems, and structural protection.

Investigation of impact of Calotropis procera extract for properties of mild steel in acidic mediums

Mild steel, widely used in gas and oil pipelines, is recognized for its remarkable capacity to absorb both internal and external energy, as well as its high tensile strength. Despite these attributes, the constant exposure to corrosive toxic substances within these pipelines poses a significant challenge. Over time, corrosion weakens the steel’s resilience to impact and increases the likelihood of failure or explosion due to the buildup of fluid pressure. To mitigate this issue, we explored an eco-friendly approach by introducing natural, non-toxic additives derived from the plant Calotropis procera (CP). The goal was to restore some of the steel's lost energy absorption capacity and enhance its resistance to corrosion and fracture.To test the effectiveness of Calotropis procera extract, we conducted weight-loss experiments using API 5L X70 steel in a solution containing 1 mol sulfuric acid and oil. We varied the concentration of CP plant extract in the solution, using 5%, 7%, 10%, and 13% to evaluate its corrosion inhibition properties. Surface examination was carried out using optical microscopy, which confirmed a corrosion inhibition rate of 50% in the CP + H₂SO₄ solution. To further investigate the mechanical performance, we performed Charpy impact tests in the same acidic environment with CP concentrations of 5%, 7%, and 10%. The results revealed that at a 10% concentration of plant extract, the steel exhibited an absorbed impact energy of 278 J, with a corresponding resilience value of 348.325 J/cm². These findings demonstrate the potential of Calotropis procera extract as an effective, sustainable solution for improving the durability of steel used in corrosive environments.

Low-Velocity Impact Behaviour of Titanium-Based Carbon-Fibre/Epoxy Laminate.

This study investigated the low-velocity impact response of titanium-based carbon-fibre/epoxy laminate (TI-CF FML). A comprehensive experimental study was carried out with impact energies ranging from 16.9 J to 91.9 J. Finite element analysis, performed using ABAQUS, was employed to elucidate the failure mechanisms of the laminate. Three distinct damage modes were identified based on the impact energy levels. The energy absorption characteristics of the TI-CF FML were analysed, revealing that maximum energy absorption is achieved and remains constant after penetration occurs. The relationship between impact force and displacement was also explored, showing that the laminate can withstand a peak force of 13.1 kN. The research on the impact resistance, damage mechanisms and energy absorption capacity of TI-CF FML provides an in-depth understanding of the impact behaviour of the laminate and its suitability for various industrial applications.

Dynamic response and damage mechanisms of 2D plain weave hybrid composites under the out-of-plane punch shear loading

A modified theoretical method for the punch shear test is derived by considering the influence of stress wave reflections caused by cross section discontinuities in the incident and transmitted bars. The dynamic punch shear behavior of 2D plain weave carbon/aramid hybrid composites was researched. The failure strength and strain are sensitive to strain rate. The stress-strain curves were obtained by the modified method. Significant shear deformation was observed under a single loading. An effective punch shear mesoscopic simulation model that accounts for the strain rate effect of the component materials was developed using the multi-scale analysis method. The model reveals the damage characteristics in the component materials. Damage modes are affected by hybridization and strain rates. The high elongation at the fracture of aramid fibers at high strain rates plays a crucial role in absorbing impact energy.

Influence of Stacking Sequence on the Mechanical Properties of Banana-Glass Fiber Hybrid Laminates for Automotive Shells

The development of composite materials using natural fibers has garnered significant global research interest. Banana fibers, due to their abundant availability and rapid growth cycle, present a promising option for composite material development. When combined with synthetic fibers to form hybrid composites, the resulting material may exhibit significantly improved properties, which is desirable for automotive body manufacturing. The hybrid properties of such composites, however, remain largely unexplored and require thorough evaluation. This study investigates the mechanical performance of hybrid laminated composites fabricated from banana and woven glass fibers bonded with epoxy resin. The composites were produced using non-crimp banana (B) fiber and woven glass (WG) fiber fabrics through the hand lay-up process with four distinct stacking sequences: [WG/B-0⁰/B-0⁰/WG], [WG/B-0⁰/B-45⁰/WG], [WG/B-0⁰/B-60⁰/WG], and [WG/B-0⁰/B-90⁰/WG]. Comprehensive mechanical testing, including tensile, flexural, impact, and hardness tests, along with environmental testing (water diffusion) was conducted in accordance with ASTM standards. Results indicated that the [WG/B-0⁰/B-0⁰/WG] configuration exhibited the highest tensile strength, while the [WG/B-0⁰/B-60⁰/WG] configuration achieved superior flexural strength. The [WG/B-0⁰/B-45⁰/WG] configuration demonstrated the highest impact strength and energy absorption. Rockwell hardness testing revealed that the average hardness numbers for all orientations were approximately 79, which is considered moderate for composite materials. Water absorption tests showed maximum water saturation in [WG/B-0⁰/B-90⁰/WG] of ∼5.5%, where the other laminates had water saturation between 4.5-4.9%. The microscopic analysis of the [WG/B-0⁰/B-45⁰/WG] laminate suggests fiber-matrix debonding and fiber pull-out as the major cause of failure under tensile and flexural loading. These findings suggest that the hybrid laminated composites, particularly the [WG/B-0⁰/B-0⁰/WG] and [WG/B-0⁰/B-45⁰/WG] configurations, exhibit mechanical properties suitable for automotive body applications.

Additive manufactured 3D re-entrant auxetic structures for enhanced impact resistance

Abstract This study presents a novel exploration of the geometric parameters within a 3D re-entrant auxetic lattice structure, specifically focusing on their unique impact energy absorption properties, which were systematically evaluated through drop weight impactor testing. Each lattice configuration was additively manufactured using stereolithography, allowing for precise control over strut thickness (t), re-entrant angle (θ), and the aspect ratio (h/l) of unit cells during both low and high energy impact scenarios. This study found that the overall auxetic behavior is predominantly controlled by the aspect ratio of the cell ribs, while the modulus is governed by rib thickness. A finite element model was subsequently developed to simulate the experimental impact loading conditions and was used to examine a wider range of parameters that were not experimentally tested. The simulated dynamic test results displayed the deformation trends and changes to the Poisson's ratio. Among the studied parameters, experimental results highlighted that a lattice structure with t = 1.6 mm, θ = 65°, and a h/l ratio = 1.8 exhibited the highest specific energy absorption (SEA) under uniaxial impact deformation with 5 Joules of impact energy. Conversely, when employing 20 Joules of impact energy revealed the greatest SEA at t = 1.0 mm, θ = 65°, and an h/l ratio of 2.2. The results demonstrate unique deformation mechanism of auxetic structures under impact loading and the capacity to adapt the 3D re-entrant lattice structure for applications requiring tailored impact energy absorption.

Influence of projectile shape on ballistic behavior of 3D shallow straight-joint woven fabrics

This study investigates the influence of projectile shape on the ballistic behavior of 3D shallow straight-joint woven fabrics (3DSSWFs). Utilizing a series of numerical simulations, we analyze the impact resistance and energy absorption capabilities of 3DSSWFs when subjected to projectiles of varying geometries. The projectile setup includes spherical, conical, flat, and hemispherical projectiles to comprehensively assess their effects on fabric deformation, damage mechanisms, and overall ballistic performance. Results indicate that projectile shape significantly affects the penetration resistance and failure modes of 3DSSWFs. Spherical projectiles tend to cause extensive delamination and localized fabric failure, whereas conical and flat projectiles exhibit different interaction dynamics, influencing the energy dissipation patterns within the fabric matrix. The findings of this study provide critical insights into the complex relationships between projectile geometry and fabric response in 3DSSWFs. By elucidating the role of projectile shape in determining the ballistic limit, energy absorption capacity, and failure mechanisms, this research contributes to the broader understanding of impact dynamics in advanced textile structures.

Study on Mechanical and Microstructural Evolution of P92 Pipes During Long-Time Operation

To investigate the mechanical properties and microstructure evolution of P92 steel during long-term service, the operated P92 main steam pipes from the first ultra-supercritical units in China were sectioned into samples representing various service durations and stresses (0# (as-received state, 1# (82,000 h, 67.3 MPa), 2# (85,000 h, 78.0 MPa), and 3# (100,000 h, 80.3 MPa)). Thereafter, a comprehensive assessment of their mechanical properties, including tensile strength, impact, hardness, and creep resistance, as well as a detailed microstructure analysis, was carried out. The effect of stress on the aging of material properties during operation is discussed. The results show that the circumferential stress caused by the increase in the internal steam pressure can significantly promote the creep life consumption of P92 steel, resulting in the degradation of mechanical properties and the expedited aging of the microstructure. The Rp0.2 and Rm of the P92 main steam pipe at room temperature and 605 °C decreased with the service time increase, reflecting the influence of stress in operation, which is expected to be used for the residual life evaluation of P92 steel. The relationship between the impact absorption energy (FATT50), Brinell hardness, and the operating time of P92 operating pipes is non-monotonic, indicating that these parameters are not sensitive indicators of material aging due to stress. The evaluation of performance degradation in P92 operating pipes due to stress-induced aging is not reliably discernible through optical metallography alone. To achieve a thorough assessment, the use of transmission electron microscopy (TEM) is essential.

Modelling and optimisation of the structural performance of lightweight polypropylene fibre-reinforced LECA concrete

Lightweight fibre-reinforced concrete integrates the advantages of lightweight aggregates with the strength-enhancing properties of fibres, resulting in a lighter composite with enhanced impact and mechanical performance. However, achieving an optimal balance between structural weight, and performance remains a challenging endeavour. This study investigates the mechanical properties, impact energy absorptions, flexural toughness, and crack resistance of lightweight fibre-reinforced concrete with the coarse aggregate entirely replaced with lightweight expanded clay aggregate (LECA). Concrete mixes containing 0 %, 0.5 %, 0.75 %, and 1.0 % Polypropylene fibre (PPF) and 10 % micro-silica were experimentally investigated. Predictions for concrete mixes with up to 2 % PPF were made using regression models developed from experimental data. The experimental and predicted results were analysed using response surface methodology. The findings reveal significant enhancements of up to 300 % and 570 % in toughness indices I5 and I10 at 1 % PPF, coupled with a 55.4 % increase in residual strength. Furthermore, an optimised slab thickness of 47 mm containing 1.73 % PPF yielded optimal impact energy absorption of 680 J and 2384 J and crack resistance of 3823 MPa and 16279 MPa at service and ultimate loading, respectively. These metrics represent improvements of 4.8, 15.2, 37, and 56 times, respectively, compared to the control samples. These substantial advancements highlight the potential of lightweight fibre-reinforced LECA concrete in engineering applications where balancing impact energy absorption, crack resistance, and structural weight is crucial. This innovative approach promises a transformative impact on the construction industry, paving the way for more efficient and resilient infrastructure.

Frontal Impact Energy Absorbers for Passenger Cars.

Road accidents cause considerable losses to road users and to society. The steady increase in the number of vehicles leads to increased traffic volume. Therefore, there is a real need to improve passenger safety by developing passive safety systems. This article presents the results of experimental tests of structures absorbing kinetic energy, which could be used in the front section of a vehicle in order to reduce the consequences of passenger car head-on collisions. A number of crash tests of selected structures were conducted under various load conditions. An analysis was carried out of parameters enabling the authors to assess the level of energy absorption by the absorbers made, and compare these to absorbers available on the market. The tests carried out made it possible to determine energy absorption capability of the crash boxes prepared and to identify a structure exhibiting the most advantageous properties from the point of view of its prospective use. Of all of the absorbers analysed, in the context of energy absorption, it was the absorber made of glass-fibre-reinforced polyphenylene sulphide that produced the most advantageous results. Nonetheless, favourable results were obtained for all of the structures tested.

Effect of heat treatment on microstructure and mechanical anisotropy of direct energy deposited Ti-6.0Al-2.5Nb-2.2Zr-1.2Mo alloy

Ti-6.0Al-2.5Nb-2.2Zr-1.2Mo alloy (Ti-6321) exhibits excellent corrosion resistance and impact toughness, which can be used as a deep-sea pressure-resistant hull. However, the alloy tends to have high strength but low plasticity, poor impact toughness, and anisotropic mechanical properties by fabricating by direct energy deposition (DED) technology. In order to improve the impact toughness of DEDed Ti-6321 alloy while reducing its anisotropy of mechanical properties, this study manipulates the microstructure and mechanical properties of the alloy through heat treatment. The research finds that with the increase of the single-stage annealing temperature within the (α+β) two-phase region, the width of the α phase increases, the Ultimate Tensile Strength (UTS) remains essentially unchanged, the Yield Strength (YS) decreases, and the impact absorption energy significantly improves. For double annealing heat treatment at two-phase region, temperature increase at the first-stage annealing enlarges the width and decreases the aspect ratio of the primary α phase. Leading to the decrease of the UTS & YS and increase of the impact absorption energy, with a conversely tendency at 1000 °C. The increase in the second-stage annealing temperature raises the size and volume fraction of the secondary α phase, causing the alloy's UTS and YS to initially rise then fall, with a slight increase in impact absorption energy. The anisotropy in the mechanical properties of DEDed Ti-6321 alloy mainly addressed from the different distribution of α phase orientations at different loading directions, and can be eliminated through sufficient β single-phase zone annealing.

Improving the Impact Resistance of Anti-Ram Bollards Using Auxetic and Honeycomb Cellular Cores

Security is a crucial matter, and when it comes to road safety, barriers are increasingly needed to protect assets and pedestrians from intentional and accidental vehicular impacts. Hollow steel tubes are commonly used to produce bollards; however, their impact resistance and energy absorption are limited. Hence, the aim of this study is to investigate whether the addition of honeycomb and auxetic cellular cores can improve the energy absorption and protection level of existing bollards. Hollow bollard, a honeycomb–core bollard and an auxetic-core bollard were numerically modeled and tested (using Simulia Abaqus software, version 2019) against the impact of M1-class vehicles (of 1500 kg mass) at five different speeds (following PAS 68:2013 British standard). Hence, 15 cases/numerical models were considered, with 5 cases for each bollard type. The results revealed that the addition of an auxetic cellular core to the bollard system could increase its energy dissipation by 52% compared to the hollow steel bollard. Moreover, the proposed auxetic anti-ram bollard system was capable of stopping an M1-class vehicular impact of 64 km/h compared to only 32 km/h when using a hollow steel bollard. To the authors’ knowledge, the use of an auxetic core, explicitly for anti-ram bollards, can be considered the novel part of this research.

Absorption of Impact and Shear Energy by Crystal Lattices of Mechanically Activated Inorganic Substances: A Review

Absorption of Impact and Shear Energy by Crystal Lattices of Mechanically Activated Inorganic Substances: A Review

The impact protection behavior of UHPC composite structure on RC columns

In order to prevent the reinforced concrete (RC) structures from being damaged under the overload impact, a new type of composite structure—ultra-high performance concrete (UHPC)–Bio-inspired honeycomb column thin-walled structure (BHTS) was designed in this paper. A scale model with a scaling factor of 1:10 was made. The experimental tests and numerical simulations of RC column and UHPC composite structure were carried out. By comparing the impact force, displacement, shear force, bending moment and energy absorption, the protective effect of the UHPC-BHTS composite structure on RC columns under lateral impact load was evaluated. Then, the failure process of RC column was analyzed, the UHPC-BHTS composite structure absorbed 76.42% of the impact kinetic energy under the higher energy input condition, the shear failure with large damage to the RC column can be converted into bending failure with small damage. At the same time, a new damage assessment method was used to evaluate the RC column. The results show that the RC column with UHPC-BHTS composite structure can effectively protects the RC column structural integrity under impact. The design and modeling methods in this research can provide a useful reference for anti-collision design in practical engineering.

Influence of nano industrial waste and short coir fiber filler on hybrid inter and intra yarn bio fiber composites

Bio-polymer composites are emerging as a feasible substitute for conventional polymers in various major fields of applications. In the current research, the impact of hybridization of inter and intra-woven natural engineering fibers namely, brown flax, white flax, and jute of different amalgamations along with commingled SCF and novel nano IW filler has been studied. The composites are manufactured by hand layup process and physical and thermomechanical characteristics of the composites are experimentally studied. The composites mingled with IW filler demonstrated better dimensional stability and mechanical properties such as maximum tensile strength of 36.74 MPa, bending strength of 82.53 MPa, and hardness of 84.89 D compared to other composites. However, elastic and flexural modulus are maximum for composite without any filler. The composites mingled with SCF filler demonstrated the highest impact strength, energy absorption, and elongation. Thermogravimetric analysis and thermal conductivity study demonstrated that the composite with SCF filler exhibited better thermal stability and thermal resistance than the other hybrid composites. Fourier transform infrared spectroscopy study confirms the interaction of hydrogen bonds with different polymers, matrices, and fillers. It is established that the weaving pattern and the filler types greatly influences the mechanical and thermal characteristics of the composites. Filler addition and fabric hybridization optimizes the catastrophic failures and enhances the thermal stability, hence becoming more suitable for small interior structural components in aerospace and automobile applications.

Improving dynamic energy absorption performance and stability loss prediction of an all-PET sandwich structure through artificial neural networks

Abstract One key characteristic that is frequently studied in composite sandwich structure mechanics is low-velocity impact performance. Single polymer composites present higher ductility when compared to traditional glass fibre and carbon fibre reinforced plastic composites (GFRP, CFRP), which makes them strong candidates for impact energy absorption. These lightweight structures are also fully recyclable due to their all-PET constituents, an important aspect when considering possible applications. In this paper an existing second order composite SrPET and PET foam sandwich structure (self-reinforced poly-ethylene terephthalate matrix and fibre) is numerically investigated for optimal structural design configuration under out-ofplane, low velocity, dynamic loading. The study explores the parametric geometry interdependencies of the structure’s configuration with respect to its energy absorption potential. The results are then compared to the quasi-static loading performance behaviour studied by M.N. Velea et all [1]. This work provides a deeper understanding of how geometry configurations can influence energy absorption capabilities highlighting structural strengths and weaknesses while exploring non-equilateral triangle configurations. The Design Space Exploration (DSE) is carried out by using an optimization algorithm for a dynamic out of plane 3D impact simulation based on the finite element (FE) method software. The synergy between DSE and FE generates a guided simulation loop that can successfully be used to train a neural network to predict the dynamic behaviour of different geometric configurations from the exploration space. Based on the data samples obtained, an artificial neural network (ANN) is built to predict the energy absorption capacity for a given set of structural design parameters, useful in experimental validation test cases.

Effective Press Folding Line Process as Producing Smart Intersection in Square Steel Pipe Structures by Using Crushed Cross Section Compactly

As a cross section of square steel pipe is crushed, the upper plate and the lower plate deform inward, and the side plates deform outward from the original square cross section shape. When the press folding line process as deformation induction is applied, the upper plate and the lower plate keep flat, and the side plates are compactly folded inward. This deformation pattern is safe without causing any harm to the surrounding area, and makes it possible to improve impact energy absorption performance by folding side plates as overlapping. Moreover, square steel pipe structures include places as pipes intersect and places to avoid interference with other parts (piping, wiring, fork claws, etc.). In such cases, the current method is to create an opening by cutting off. At that time, the structural strength will decrease, so reinforcing materials are often installed as a countermeasure. On the other hand, if the opening is processed by laterally impact crushing using the press folding line process proposed in this paper, a crushed part will remain, suppressing the decrease in structural strength, and this can be handled without adding reinforcing material to be a smart intersection. This paper shows the findings based on experimental data, FEM (Finite Element Method) results on processing conditions for inward deforming side plates of square steel pipes and evaluation of impact energy absorption performance in laterally impact crushing.

Flat silk cocoons: A candidate material for fabricating lightweight and impact-resistant composites

The utilization of silk cocoons in the production of lightweight and tough composites has been gaining increasing attention. However, the limited applications of normal silk cocoons (NSC) are attributed to their small size and irregular shape. To overcome this deficiency, flat silk cocoons (FSC) with a similar structure and controllable size were prepared. Next, we systematically characterized and compared the microstructures, morphologies, compositions, thermal properties, and mechanical properties of FSC with NSC. Subsequently, FSC was successfully utilized to fabricate a novel silk fibroin fiber reinforced sericin matrix composite (HPFSC) using a hot pressing method, followed by the analysis of its microstructure evolution, mechanical properties, failure modes, and theoretical modeling. This composite has outstanding mechanical properties including hardness, modulus, and strength. HPFSC has a relatively low density of ~1.3 g/cm3, whose absorbed impact energy can reach a maximum value of 11.1 J/mm, exceeding that of most engineering materials, such as aluminum alloy, ceramics, glass, and carbon fiber composites. The exceptional performance of HPFSC can be attributed to the reduced porosity, enhanced bonding between silk fibroin fibers facilitated by sericin, and their structural transformation. This study offers valuable guidance for the fabrication of lightweight and impact-resistant composites using flat silk cocoons.