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We present a series of experiments on the response of additive manufactured (AM) tantalum to dynamic loading, specifically the spall strength. Rectangular plates of AM tantalum were produced, with subsequent characterization revealing a highly anisotropic microstructure. Samples were taken from these plates to investigate the effect of anisotropy on the spall strength: the resistance to high strain-rate tensile damage. A conventional, wrought tantalum sample, possessing an equiaxed microstructure, was also tested to serve as a control. Shock loading was performed via light gas-gun flyer-plate impact experiments, with laser velocimetry on the rear of the samples to record the shock wave profiles and soft-recovery techniques to allow post-mortem analysis. In general, the AM samples were found to have a higher Hugoniot elastic limit, the dynamic yield strength under shock loading, while having a reduced spall strength, when compared to the wrought tantalum samples. [ABSTRACT FROM AUTHOR]

Materials subjected to dynamic environments experience a complex and wide range of stress, strain, and strain-rate conditions. To have confidence in material models, an accurate, predictive capability is required. In this study, we present a series of flyer-plate impact tests on well characterized, high purity tantalum. The shock-waves generated at impact release from the free-surfaces, reflect, and interact to produce incipient spall fracture. By varying the flyer-plate material and impact velocity, both the peak stress and the strain-rate in the samples were controlled independently. Velocimetry was used on the rear free-surface of the samples to measure the shock-response and the spall strength. While this measurement provided the same spall strength for all cases, at approximately 5.1 GPa, when the samples were sectioned during post-mortem, the quantity and distribution of internal damage was markedly different. For the high-strain rate cases, voids remained small and isolated, whereas in the lower strain-rate experiments, the spall damage was far more localized, with a well-defined continuous spall plane. With the use of hydrocode simulations, this was discovered to result from how the different release rates affect the interaction volume inside the sample. These results highlight the importance of careful sample recovery, and the risks of relying solely on free-surface velocity measurements. [ABSTRACT FROM AUTHOR]

We present a study on the spall strength of additive manufactured (AM) Ti-6Al-4V. Samples were obtained from two pieces of selective laser melted (SLM, a powder bed fusion technique) Ti-6Al-4V such that the response to dynamic tensile loading could be investigated as a function of the orientation between the build layers and the loading direction. A sample of wrought bar-stock Ti-6Al-4V was also tested to act as a baseline representing the traditionally manufactured material response. A single-stage light gas-gun was used to launch a thin flyer plate into the samples, generating a region of intense tensile stress on a plane normal to the impact direction. The rear free surface velocity time history of each sample was recorded with laser-based velocimetry to allow the spall strength to be calculated. The samples were also soft recovered to enable post-mortem characterization of the spall damage evolution. Results showed that when the tensile load was applied normal to the interfaces between the build layers caused by the SLM fabrication process the spall strength was drastically reduced, dropping to 60% of that of the wrought material. However, when loaded parallel to the AM build layer interfaces the spall strength was found to remain at 95% of the wrought control, suggesting that when loading normal to the AM layer interfaces, void nucleation is facilitated more readily due to weaknesses along these boundaries. Quasi-static testing of the same sample orientations revealed a much lower degree of anisotropy, demonstrating the importance of rate-dependent studies for damage evolution in AM materials. [ABSTRACT FROM AUTHOR]

For ductile metals, dynamic fracture occurs principally through void nucleation, growth, and coalescence at heterogeneities in the microstructure. Previous experimental research on high purity metals has shown that microstructural features, such as grain boundaries, inclusions, vacancies, and heterogeneities, can act as initial void nucleation sites. In addition, other research on two-phase materials has also highlighted the importance of the properties of a second phase itself in determining the dynamic response of the overall material. However, previous research has not investigated the effects of the distribution of a second phase on damage nucleation and evolution. To approach this problem in a systematic manner, two copper alloys with 1% lead materials, with the same Pb concentration but different Pb distributions, have been investigated. A new CuPb alloy was cast with a more homogeneous distribution of Pb as compared to a CuPb where the Pb congregated in large "stringer" type configurations. These materials were shock loaded at ~1.2 GPa and soft recovered. In-situ free surface velocity information, and post mortem metallography, reveals that even though the spall strength of both the materials were similar, the total extent and details of damage in the materials varied by 15%. This suggests that altering the distribution of Pb in the Cu matrix leads to the creation of more void nucleation sites and also changed the rate of void growth. [ABSTRACT FROM AUTHOR]

The response of polycrystalline metals, which possess adequate mechanisms for plastic deformation under extreme loading conditions, is often accompanied by the formation of pores within the structure of the material. This large deformation process is broadly identified as progressive with nucleation, growth, coalescence, and failure the physical path taken over very short periods of time. These are well known to be complex processes strongly influenced by microstructure, loading path, and the loading profile, which remains a significant challenge to represent and predict numerically. In the current study, the influence of loading path on the damage evolution in high-purity tantalum is presented. Tantalum samples were shock loaded to three different peak shock stresses using both symmetric impact, and two different composite flyer plate configurations such that upon unloading the three samples displayed nearly identical "pull-back" signals as measured via rear-surface velocimetry. While the "pull-back" signals observed were found to be similar in magnitude, the sample loaded to the highest peak stress nucleated a connected field of ductile fracture which resulted in complete separation, while the two lower peak stresses resulted in incipient damage. The damage evolution in the "soft" recovered tantalum samples was quantified using optical metallography, electron-back-scatter diffraction, and tomography. These experiments are examined numerically through the use of a model for shock-induced porosity evolution during damage. The model is shown to describe the response of the tantalum reasonably well under strongly loaded conditions but less well in the nucleation dominated regime. Numerical results are also presented as a function of computational mesh density and discussed in the context ofimproved representation of the influence of material structure upon macro-scale models of ductile damage. [ABSTRACT FROM AUTHOR]

Previous experimental research has shown that microstructural features such as interfaces, inclusions, vacancies, and heterogeneities can all act as void nucleation sites. However, it is not well understood how important these interfaces are to damage evolution and failure as a function of the surrounding parent materials. In this work, we present results on three different polycrystalline materials: (1) Cu, (2) Cu-24 wt. %Ag, and (3) Cu-15 wt.%Nb which were studied to probe the influence of bi-metal interfaces on void nucleation and growth. These materials were chosen due to the range of difference in structure and bulk properties between the two phases. The initial results suggest that when there are significant differences between the bulk properties (for example: stacking fault energy, melting temperature, etc.) the type of interface between the two parent materials does not principally control the damage nucleation and growth process. Rather, it is the "weaker" material that dictates the dynamic spall strength of the overall two-phase material. [ABSTRACT FROM AUTHOR]

A longstanding question in the field of multi-material behavior pertains to the treatment of interfaces possessing finite frictional strength under high dynamic pressures and shear. Here, we examine the effects of constrained interface sliding on local deformation near the boundary using new, highresolution measurements combined with simulations to infer friction strength. The experiments use laser driven plate impacts at the Los Alamos National Laboratory TRIDENT Laser Facility to launch a shock wave into a target consisting of a central cylindrical plate of Be and an outer ring of Cu oriented, such that the shock propagates at nearly a 90° angle to the interface normal producing a large velocity gradient across the material boundary. Impact experiments were performed on targets that underwent diffusion bonding of the two materials and on targets that were only press fit together. Friction-induced surface deformation was diagnosed using line-imaging velocity interferometry and surface Transient Imaging Displacement Interferometry in the immediate region of the interface. In these studies, we observed a significant behavioral change in both simulations and experiments between targets with diffusion bonded interfaces and those that were press fit. Bonded targets exhibited a mutual dragging between the Be and Cu parts throughout the entire experiment, whereas unbonded targets displayed a surface slope reversal on the Cu side of the interface, which simulations suggest arise due to altered wave interactions from a 3× lower frictional force compared to the bonded interface. [ABSTRACT FROM AUTHOR]