Experimental Study on the Impact Compression Properties of Aluminum Honeycomb with Gradient-Thickness Cell Walls Using a Three-Factor Orthogonal Matrix Design

A novel honeycomb with gradient-thickness cell walls (HGTCWs) is fabricated through chemical etching to achieve progressive thickness reduction in the cell walls. This engineered honeycomb demonstrates superior energy absorption by effectively eliminating the peak load during the linear elastic stage of the load-displacement curve under impact loading, thereby preventing premature structural failure caused by excessive instantaneous loads. To systematically investigate the impact compression mechanics, energy absorption characteristics, and key influencing factors of aluminum HGTCWs, a three-factor orthogonal array of low-velocity impact experiments was designed. The design of experimental parameters for the impact test has taken into account the impact mass, impact velocity, and etching height. Comparative analysis assessed how these factors influence energy absorption performance. Results reveal that chemical etching-induced thickness gradient modification effectively suppresses peak load generation. Load-displacement curves exhibit distinct bilinear characteristics: an initial single linear phase when compression displacement is below the etching height, followed by a dual-linear phase with an inflection point at the gradient height. Time-velocity profiles during impact primarily consist of an initial nonlinear deceleration phase followed by a linear deceleration phase. Range analysis and analysis of variance identify impact velocity as the dominant factor influencing the energy absorption characteristics of HGTCWs.