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For additive manufacturing (AM), the certification and qualification paradigm needs to evolve as there exists no “ASTM-type” additive manufacturing certified process or AM-material produced specifications. Accordingly, utilization of AM materials to meet engineering applications requires quantification of the constitutive properties of these evolving materials in comparison to conventionally-manufactured metals and alloys. Cylinders of 316L SS were produced using a LENS MR-7 laser additive manufacturing system from Optomec (Albuquerque, NM) equipped with a 1kW Yb-fiber laser. The microstructure of the AM-316L SS is detailed in both the as-built condition and following heat-treatments designed to obtain full recrystallization. The constitutive behavior as a function of strain rate and temperature is presented and compared to that of nominal annealed wrought 316L SS plate. The dynamic damage evolution and failure response of all three materials was probed using flyer-plate impact driven spallation experiments at a peak stress of 4.5 GPa to examine incipient spallation response. The spall strength of AM-produced 316L SS was found to be very similar for the peak shock stress studied to that of annealed wrought or AM-316L SS following recrystallization. The damage evolution as a function of microstructure was characterized using optical metallography.

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]

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]

Widespread research over the past five decades has provided a wealth of experimental data and insight concerning the shock hardening, damage evolution, and the spallation response of materials subjected to square-topped shock-wave loading profiles. However, fewer quantitative studies have been conducted on the effect of direct, in-contact, high explosive (HE)-driven Taylor wave (unsupported shocks) loading on the shock hardening, damage evolution, or spallation response of materials. Systematic studies quantifying the effect of sweeping-detonation wave loading are yet sparser. In this study, the shock hardening and spallation response of Ta is shown to be critically dependent on the peak shock stress and the shock obliquity during sweeping-detonation-wave shock loading. Sweeping-wave loading is observed to: a) yield a lower spall strength than previously documented for 1-D supported-shock-wave loading, b) exhibit increased shock hardening as a function of increasing obliquity, and c) lead to an increased incidence of deformation twin formation with increasing shock obliquity.

The goal of this project is to produce a damage model forspallation in metals informed by the polycrystalline grain structure at themesoscale. Earlier damage models addressed the continuum macroscale in whichthese effects were averaged out. In this work we focus on cross sectionsfrom recovered samples examined with EBSD (electron backscattereddiffraction), which reveal crystal grain orientations and voids. We seek tounderstand the loading histories of specific sample regions by meshing upthe crystal grain structure of these regions and simulating the stress,strain, and damage histories in our hydrocode, FLAG. The stresses and strainhistories are the fundamental drivers of damage and must be calculated. Thecalculated final damage structures are compared with those from therecovered samples to validate the simulations.

For additive manufacturing (AM) of metallic materials, the certification and qualification paradigm needs to evolve as there is currently no broadly accepted “ASTM- or DIN-type” additive manufacturing certification process or AM-produced material specifications. Accordingly, design, manufacture, and subsequent implementation and insertion of AM materials to meet engineering applications requires detailed quantification of the constitutive (strength and damage) properties of these evolving materials, across the spectrum of metallic AM methods, in comparison/contrast to conventionally-manufactured metals and alloys. For this study, cylindrical samples of 316L SS were produced using a LENS MR-7 laser additive manufacturing system from Optomec (Albuquerque, NM) equipped with a 1 kW Yb-fiber laser. The microstructure of the AM-316L SS was characterized in both the “as-built” AM state and following a heat-treatment designed to obtain full recrystallization to facilitate comparison with annealed wrought 316L SS. The constitutive behavior as a function of strain rate and temperature was characterized and is compared to that of annealed wrought 316L SS plate material. The dynamic shock-loading-induced damage evolution and failure response of all three 316L SS materials was quantified using flyer-plate impact driven spallation experiments at peak stresses of 4.7 and 6.5 GPa. The spall strength of AM-produced 316L SS and the recrystallized-AM-316L SS were found to decrease with increasing peak shock stress while the annealed wrought 316L SS spall strength remained essentially constant. The damage evolution, characterized using optical metallography and electron-backscatter diffraction (EBSD), was found to vary significantly across the three 316L SS microstructures while the three samples loaded to a peak shock stress of 6.5 GPa displayed only ∼12% differences in spall strength. [ABSTRACT FROM AUTHOR]

A new specimen geometry, the compact forced-simple-shear specimen (CFSS), has been developed as a means to achieve simple shear testing of materials over a range of temperatures and strain rates. The stress and strain state in the gage section is designed to produce essentially “pure” simple shear, mode II in-plane shear, in a compact-sample geometry. The 2-D plane of shear can be directly aligned along specified directional aspects of a material's microstructure of interest; i.e., systematic shear loading parallel, at 45°, and orthogonal to anisotropic microstructural features in a material such as the pancake-shaped grains typical in many rolled structural metals, or to specified directions in fiber-reinforced composites. The shear-stress shear-strain response and the damage evolution parallel and orthogonal to the pancake grain morphology in 7039-Al are shown to vary significantly as a function of orientation to the microstructure. [ABSTRACT FROM AUTHOR]

The equations of a physical constitutive model for material stress within tantalum grains were solved numerically using a tetrahedrally meshed volume. The resulting output included a scalar vonMises stress for each of the more than 94,000 tetrahedra within the finite element discretization. In this paper, we define an intricate statistical model for the spatial field of vonMises stress which uses the given grain geometry in a fundamental way. Our model relates the three-dimensional field to integrals of latent stochastic processes defined on the vertices of the one- and two-dimensional grain boundaries. An intuitive neighborhood structure of the said boundary nodes suggested the use of a latent Gaussian Markov random field (GMRF). However, despite the potential for computational gains afforded by GMRFs, the integral nature of our model and the sheer number of data points pose substantial challenges for a full Bayesian analysis. To overcome these problems and encourage efficient exploration of the posterior distribution, a number of techniques are now combined: parallel computing, sparse matrix methods, and a modification of a block update strategy within the sampling routine. In addition, we use an auxiliary variables approach to accommodate the presence of outliers in the data., Competing Interests: No potential conflict of interest was reported by the authors., (© 2019 Triad National Security, LLC, operator of the Los Alamos National Laboratory.)

Endovascular stenting appears to be an appealing treatment modality to selected complex intracranial aneurysms. However, stents currently used for endovascular treatment are not specifically designed for the cerebrovasculature. Stent parameters, such as porosity and filament size, have to be carefully optimized for long-term successful treatment. We investigated the influence of the stent filament size on the intraaneurysmal flow dynamics in a sidewall aneurysm model in vitro. Three helical stents with 76% porosity but different filament sizes of 178, 153, and 127 microm were studied using particle image velocimetry. Twenty-four pulsatile flow conditions were investigated. The results show that stenting significantly reduces intra-aneurysmal vorticity and the mean circulation inside the aneurysm is reduced to less than 3% of its value before stenting. For constant porosity, a further reduction of the mean circulation, up to 30% can be obtained by reducing the filament diameter. For a constant Womersley number, this further reduction is accentuated with increase in the peak Reynolds number. Further reduction in the mean circulation inside the aneurysm was not achieved for the 127 microm stent. With further reduction in filament diameter, the helical stent filaments positioned against the aneurysm neck started wavering with the flow transferring added momentum into the aneurysm. For stents of smaller filament diameter, a supporting ultrastructure is required.