Systematic structural optimization of axial impact performance of 3D angle-interlock tubular woven composites through yarn configuration innovations

Thin-walled tubular composites, known for their exceptional impact resistance, serve as critical structural components in load-bearing or energy absorption applications. Their superior performance is primarily determined by structural design. In this study, a systematic structural optimization of 3D angle-interlock tubular woven composites (3DATWCs) was performed through yarn configuration innovations and the axial impact performances of 3DATWCs were experimentally investigated. The yarn configuration innovations include the adjustments to the warp lining yarn proportion and weft density, and the introduction of surface constraint yarns. The axial impact resistance and impact stability of 3DATWC are significantly enhanced after the systematic optimization. Additionally, the experimental results reveal a nonlinear relationship between the axial impact performance of 3DATWC and the warp lining yarn proportion. Under multiple low-energy impacts and single high-energy impact, different structures exhibit significant variations in axial impact performance and damage morphologies. Overall, the structures T and T+ demonstrate exceptional mechanical performance and superior damage resistance under axial impact without increasing processing difficulty. Compared to the conventional structure, the ultimate stress of optimized 3DATWC in three consecutive low-energy impacts can increase by 71.6 %, 379.5 % and 316.2 % respectively, and the ultimate stress of optimized 3DATWC in single high-energy impact can increase by 135.9 %.