LAUSR

The hybrid sandwich structures possessing composite faces and an aluminum foam (ALF) core exhibit lightweight and superior impact resistance. However, limited studies pay attention to the mechanical behavior of hybrid sandwich beams with various ALF densities. The present article has focused on the influence of foam densities on the quasi‐static and low‐velocity impact (LVI) behaviors of hybrid sandwich beams with aramid‐fiber‐reinforced polymer (AFRP) faces and ALF core. The failure mode, loading response, and energy absorption of sandwich beams have been obtained experimentally and the failure map with a wide range of dimensional configurations has been established theoretically. Increasing core density significantly enhances the load‐carrying capacity of the sandwich beam, and the enhanced effect becomes more obvious for a thicker core. The medium‐density ALFs provide the maximum specific energy absorption, while the high‐density ALFs offer the highest energy absorption for hybrid sandwich beams. The applicability of core densities in hybrid sandwich structures is provided. Normal strain distribution under quasi‐static loading is analyzed using DIC. AFRP face microbuckling provides higher impact resistance than core failure. The applicability of core density in hybrid sandwich structures is given.