Search

Additive manufacturing has the potential to repair high value components, saving significant time and resources; however, the level of reliability and performance of additive repairs is still relatively unknown. In this work, the structure–property and performance of laser wire additive manufacturing repairs in 1100 aluminum are investigated. Two types of intentional damage are inflicted on the samples and subsequently repaired with pulsed laser deposition additive manufacturing. Quasi-static (10 − 3 s − 1 ) and high strain-rate (10 − 3 s − 1 ) mechanical testing is carried out with in situ diagnostics and post-mortem imaging. The results show that while the quasi-static strength and ductility of samples with a repaired region are lower than a pristine sample, the dynamic strength under shock loading is comparable. This work highlights both the potential utility of additive manufacturing for repair purposes, the significant risk of compromised performance of additive parts under specific conditions, and the need to test at varying strain rates to fully characterize material performance. [ABSTRACT FROM AUTHOR]

In this work, the Common Model of Multi-phase Strength and Equation of State (CMMP) model was applied to tin. Specifically, calibrations of the strength-specific elements of the CMMP foundation were developed with a combination of experiments and theory, and then the model was validated experimentally. The first element of the foundation is a multi-phase analytic treatment of the melt temperature and the shear modulus for the solid phases. These models were parameterized for each phase based on ab initio calculations using the software VASP (Vienna Ab initio Simulations Package) based on density functional theory. The shear modulus model for the ambient β phase was validated with ultrasonic sound speed measurements as a function of pressure and temperature. The second element of the foundation is a viscoplastic strength model for the β phase, upon which strength for inaccessible higher-pressure phases can be scaled as necessary. The stress–strain response of tin was measured at strain rates of 10 − 3 to 3 × 10 3 s − 1 and temperatures ranging from 87 to 373 K. The Preston–Tonks–Wallace (PTW) strength model was fit to that data using Bayesian model calibration. For validation, six forward and two reverse Taylor impact experiments were performed at different velocities to measure large plastic deformation of tin at strain rates up to 10 5 s − 1 . The PTW model accurately predicted the deformed shapes of the cylinders, with modest discrepancies attributed to the inability of PTW to capture the effects of twinning and dynamic recrystallization. Some material in the simulations of higher velocity Taylor cylinders reached the melting temperature, thus testing the multiphase model because of the presence of a second phase, the liquid. In simulations using a traditional modeling approach, the abrupt reduction of strength upon melt resulted in poor predictions of the deformed shape and non-physical temperatures. With CMMP, the most deformed material points evolved gradually to a mixed solid–liquid but never a fully liquid state, never fully lost strength, stayed at the melt temperature as the latent heat of fusion was absorbed, and predicted the deformed shape well. [ABSTRACT FROM AUTHOR]

Additive manufacturing has the potential to repair damaged parts, but the performance of additive materials under high strain rate loading is still uncertain—especially with the added complexity of an interface with an existing wrought material. In this work, 304L stainless steel samples were intentionally damaged and then repaired with wire-fed laser additive manufacturing. The samples were subjected to shock loading to generate incipient spall. Velocimetry and post-mortem metallography results show that when the additive repair process parameters are optimized to reduce porosity and match the equation of state of the original material, the influence of the repair region on the shock propagation is negligible. The free-surface velocity profile and internal damage morphology of the repaired sample are shown to be practically identical to the pristine material. [ABSTRACT FROM AUTHOR]

In this work, expanding cylinder experiments are performed using a gas gun on the aluminum 6061 alloy to understand the dynamic deformation and failure behavior of this material in the presence of surface defects in the form of scratches. The experiments are then modeled with the modified Tepla (for tensile plasticity) model, which is equipped with the damage yield function of Gurson ["Continuum theory of ductile rupture by void nucleation and growth: Part I—Yield criteria and flow rules for porous ductile media," (1977)] and Tvergaard and Needleman [Acta Metall. 32(1), 157–169 (1984)], over-stress viscosity [F. Addessio and J. Johnson, J. Appl. Phys. 74(3), 1640–1648 (1993)], and the underlying viscoplastic model of Preston et al. [J. Appl. Phys. 93(1), 211–220 (2003)] (Preston–Tonks–Wallace model) for the dense material. The Tepla model parameters were calibrated using the Bayesian approach against experimentally measured free-surface velocity data obtained from plate impact experiments on the aluminum 6061 alloy. The evolution of radial expansion and shapes of the deformed cylinder from the simulations on a pristine cylinder wall and a cylinder wall with a longitudinal surface defect shows excellent agreement with the corresponding experimental results. Finally, the role of surface defect size and cylinder wall geometry on the dynamic strength of the cylinder wall was also investigated through a series of simulations. [ABSTRACT FROM AUTHOR]

It is well known that spall failure strongly depends on the microstructure of a material. There have been numerous studies to study the effect of grain size on the overall spall strength and the total amount of damage in single element metals like copper. However, such systematic studies remain rare in two-phase materials and alloys. In this work, two incipient spall experiments were performed on a Cu–1%Pb alloy to understand the effect of grain size on the damage and failure in a two-phase material. Overall, these results showed that even though the spall strength did not change as a function of grain size, there were significant differences in the total amount of damage as a function of grain size. A clear increase in the total damage present in the material was seen as the grain size was increased from 32 to either 70 or 75 μm in either of the experiments. This difference was attributed to variations in the void growth rate as the grain size was increased. [ABSTRACT FROM AUTHOR]

Using molecular dynamics simulations, we investigate the effect of vacancies and dislocations on the dynamic response of single crystal tantalum to shock loading along the ⟨ 110 ⟩ axis. A Hugoniostat technique is employed, for which a series of states along the Hugoniot are sampled by many individual simulations. We show that defects have a limited effect on the shock/particle velocity relationship and that the shock pressure/volume relationship can be well predicted by taking into account the changes in the initial density and sound speeds of the samples. The principal effect of initial defects is the activation of heterogeneous dislocation nucleation and expedited dislocation multiplication during shock. The heat generated by plastic work, caused by defects moving through the lattice, is substantial. The result is significantly divergent final shock temperatures for different initial defect concentrations and pronounced changes in the resultant shock melting temperatures. The motion of dislocations also leaves behind a noninconsequential concentration of vacancies that is quantified. [ABSTRACT FROM AUTHOR]

Spall fracture is a high-rate tensile damage phenomenon associated with impulsive and shock-load events. Typically, the material undergoes a sequence of compression followed by release into high rate (on the order of 104 s-1 and up) tension, causing voids to nucleate and grow, which can then coalesce into a crack and the material fails. We present a series of experiments on high purity, well characterized tantalum samples subjected to shock-loading via gas-gun plate impact. Through careful selection of the flyer-plate velocity and material we have independent control over the peak compressive stress and the tensile strain rate in the sample. At all times, the spall damage remains incipient, i.e. in the early stages of void formation and the material does not fully fracture. Velocimetry was used on the rear of the sample to record the wave-profiles and determine spall strength. Soft recovery and sectioning of the samples allowed the internal damage to be observed, quantifying the damage amount, distribution, and relationship to microstructural features with both optical and electron based microscopy.

Theoretical analysis of Richtmyer-Meshkov instability (RMI) experiments for solid strength shows that the strain rate for a given shock should be inversely proportional to the length scale of the sine wave perturbations when η_{0}k, the nondimensional amplitude to wavelength ratio, is held fixed. To isolate the effect of strain rate on strength, free-surface RMI specimens of annealed copper were prepared with three perturbation regions with the same η_{0}k but different length scales, characterized by the wavelength λ varying by a factor of 4.9 from 65 to 130 to 320µm. Three such targets with different fixed η_{0}k^{'}s were impacted to a shock pressure of 25 GPa, and the instability evolution was measured with photon Doppler velocimetry. Strengths estimated by comparing hydrocode simulation to the data increased from 700 to 1200 MPa as λ decreased. The different η_{0}k targets exercised increasing amounts of plastic strain yet showed no evidence of strain hardening. Physical regime sensitivity analysis determined that for 320-65µm wavelength perturbations, the effective strain rates increased from 8.7×10^{6} to 3.3×10^{7}s^{-1}, a factor of 3.8. Thus, the predicted strain rate scaling was mostly achieved but slightly suppressed by increased strength at higher rates. The RMI strength estimates were plotted against constitutive testing data on copper from the literature to show striking evidence of the strength upturn at higher strain rates.