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High-Strain-Rate Material Behavior and Adiabatic Material Instability in Impact of Micron-Scale Al-6061 Particles

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A Correction to this article was published on 26 March 2018

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Abstract

Impact of spherical particles onto a flat sapphire surface was investigated in 50-950 m/s impact speed range experimentally and theoretically. Material parameters of the bilinear Johnson–Cook model were determined based on comparison of deformed particle shapes from experiment and simulation. Effects of high-strain-rate plastic flow, heat generation due to plasticity, material damage, interfacial friction and heat transfer were modeled. Four distinct regions were identified inside the particle by analyzing temporal variation of material flow. A relatively small volume of material near the impact zone becomes unstable due to plasticity-induced heating, accompanied by severe drop in the flow stress for impact velocity that exceeds ~ 500 m/s. Outside of this region, flow stress is reduced due to temperature effects without the instability. Load carrying capacity of the material degrades and the material expands horizontally leading to jetting. The increase in overall plastic and frictional dissipation with impact velocity was found to be inherently lower than the increase in the kinetic energy at high speeds, leading to the instability. This work introduces a novel method to characterize HSR (109 s−1) material properties and also explains coupling between HSR material behavior and mechanics that lead to extreme deformation.

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Change history

  • 26 March 2018

    An acknowledgement was omitted by the authors. The following should have been included with the published article.

Abbreviations

A :

Static yield stress, MPa

A c :

Contact area, m2

B :

Coefficient of strain hardening, MPa

c :

Specific heat, J/kg K

C :

Bilinear strain rate coefficient

D1 :

Height of deformed particle, m

D2 :

Diameter of deformed particle, m

D p :

Diameter of particle, m

e :

Coefficient of restitution

E :

Elastic modulus, error between experiment and simulation aspect ratios

E k :

Kinetic energy of particle, J

E r :

Recovered strain energy, J

k :

Thermal conductivity, W/m K

m :

Index of thermal softening

m p :

Mass of particle, kg

n :

Index of strain-rate hardening

R e :

Experimental aspect ratio

R s :

Simulated aspect ratio

T :

Temperature, K

T * :

Homologous temperature

T m :

Melting temperature, K

T R :

Reference temperature, K

U p :

Energy dissipated due to plastic action, J

v i :

Impact velocity, m/s

v r :

Rebound velocity, m/s

W f :

Work done against friction, J

x :

Optimization variable vector

α :

Thermal expansion ratio, K−1

β :

Inelastic heat fraction

\(\varepsilon_{f}\) :

Failure shear strain

\(\varepsilon_{\text{p}}\) :

Equivalent plastic strain

\(\dot{\varepsilon }_{ 0}\) :

Reference strain rate, s−1

\(\dot{\varepsilon }_{\text{c}}\) :

Critical reference strain rate, s−1

\(\dot{\varepsilon }_{\text{p}}\) :

Equivalent plastic strain rate, s−1

µ :

Kinetic friction coefficient

ν :

Poisson’s ratio

ρ :

Mass density, kg/m3

σ Y :

Yield (flow) stress, MPa

r :

Material properties at room temperature

CS:

Cold spray

FEA:

Finite element analysis

GZ:

Gao-Zhang

HSR:

High strain rate

JC:

Johnson–Cook

KHL:

Khan–Huang–Liang

LIPIT:

Laser-induced projectile impact test

PDMS:

Polydimethylsiloxane

PTW:

Preston–Tonk–Wallace

VA:

Voyiadjis–Abed

ZA:

Zerilli–Armstrong

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Authors and Affiliations

  1. Department of Mechanical and Industrial Engineering, Northeastern University, Boston, MA, 02115, USA

    Qiyong Chen, Arash Alizadeh, Andrew Gouldstone & Sinan Müftü

  2. Department of Mechanical and Industrial Engineering, University of Massachusetts, Amherst, MA, 01002, USA

    Wanting Xie & Jae-Hwang Lee

  3. Department of Physics, University of Massachusetts, Amherst, MA, 01002, USA

    Wanting Xie

  4. United Technologies Research Center, East Hartford, CT, 06108, USA

    Xuemei Wang

  5. United States Army Research Laboratory, Aberdeen Proving Ground, Aberdeen, MD, 21005, USA

    Victor Champagne

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  1. Qiyong Chen
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Chen, Q., Alizadeh, A., Xie, W. et al. High-Strain-Rate Material Behavior and Adiabatic Material Instability in Impact of Micron-Scale Al-6061 Particles. J Therm Spray Tech 27, 641–653 (2018). https://doi.org/10.1007/s11666-018-0712-4

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