Deformation and damage of sintered low-porosity aluminum under planar impact: microstructures and mechanisms

Plate impact experiments are conducted to study compaction and spallation of 5% porosity aluminum. Free surface velocity histories, the Hugoniot elastic limit (HEL), and spall strengths are obtained at different peak stresses and pulse durations. Scanning electron microscopy, electron backscatter diffraction, and X-ray computed tomography are used to characterize 2D and 3D microstructures. 3D void topology analyses yield rich information on size distribution, shape, orientation, and connectivity of voids. HEL decreases/increases with sample thickness/impact velocity and approaches saturation. Its tensile strength increases with increasing peak stress and shock-induced densification. With the enhanced compaction under increasing impact velocities, spall damage modes change from growth of original voids to inter-particle crack propagation and to “random” nucleation of new voids. Such a change in damage mechanism also gives rise to a distinct decrease in damage extent at high impact velocities. Compaction induces strain localizations around the original voids, while subsequent tension results in grain refinement, and shear deformation zones between staggered cracks.