A Semi-Analytical and Data-Calibrated Hybrid Model for Predicting Residual Deformation of Shape Memory Alloy Honeycombs

Future lunar missions, like the International Lunar Research Station (ILRS), demand single-launch multi-point operations, urgently requiring reusable energy-absorbing structures. Integrating shape memory alloy (SMA) into honeycombs offers a promising solution; however, deformation exceeding the SMA’s recoverable limit induces structural residual deformation, altering the configuration and degrading subsequent energy absorption. To address this, we propose a semi-analytical, data-calibrated hybrid model predicting SMA honeycomb residual deformation. A four-stage linear constitutive model is established capturing superelasticity and martensitic yielding. Cell walls are idealized as equivalent beams. Using layered fiber integration and numerical interpolation, a nonlinear moment–curvature relationship is constructed, enabling rapid structural residual deflection evaluation from material residual strains. Finite element results confirm that initial residual deformation stabilizes the honeycomb into a reusable configuration, governing subsequent plateau stresses. Calibrated by uniaxial test data, the proposed model accurately predicts residual deformation ratios and reusable plateau stresses with errors within 8%. By bridging material-level strain with structural-level deformation, this approach circumvents computationally expensive full-scale simulations and costly experimental trials, providing a highly efficient tool for designing reusable SMA absorbers.