In view of the fact that weld strength is usually lower than the material strength, and geometric characteristics of parts is affected by the significant features
when using the superplastic forming and diffusion-bonded process to build the hollow warren thin wall structures, and based on the study of the deformation of diffusion bonding components and failure mechanism of bonding seam, this paper proposed a novel method in which thick shell elements were used to model diffusion bonded components. Moreover, the tied contact with failure mode was used to model bonding seam physical properties, and its strength parameters were related to geometric characteristics. The impact tests of hollow warren thin wall structures based on superplastic forming were performed, and numerical simulation results were compared with the test data. The results show that the method proposed in this paper can be used for dynamic analysis of model bonded hollow warren structures.