Numerical simulation study on mesoscopic metallic foam core sandwich panels under hypervelocity impact

Due to its lightweight and superior energy absorption characteristics, metallic foams are exceptionally suitable for the protective shielding of spacecraft against debris. The mesoscopic structure of such a foam plays a pivotal role in enhancing its outstanding protective performance. Numerical simulations permit us to explore the damage mechanism of its internal structure and the evolving characteristics of debris clouds. By adopting the three-dimensional Voronoi tessellation in conjunction with the algorithm of background mesh mapping, this study constructed mesoscopic finite element models that accurately reflect the internal randomness and variability in ligament width within the metallic foam. Subsequently, numerical simulations were executed employing the FE-SPH adaptive method within the LS-DYNA. Comparative experimental cases substantiated the validity of the simulations, and an exhaustive mesh sensitivity analysis was conducted. Optimizing results from these simulations following a normal impact, we delved into the propagation of stress waves within the foam core, alongside the subsequent internal structural damage. Furthermore, we explored the damage mechanism of foam sandwich panels subjected to hypervelocity impacts. According to the fragmentation process of the projectile and the evolution of debris clouds, it was discerned that the random internal structure of the foam engenders an asymmetric and skewed debris cloud, dispersing its energy and culminating in multiple concentrated particle clusters with a predilection towards a particular direction. Tracking the velocity fluctuations of these ‘dominant particles’ and the inflicted damage on the rear facesheet revealed that the agglomerated tiny fragments of the projectile are primarily responsible for perforating the rear facesheet.