
- Matter and Radiation at Extremes
- Vol. 7, Issue 1, 018201 (2022)
Abstract
I. INTRODUCTION
The development of modern industry has prompted the exploration of material properties under extremely complex service conditions. For materials ranging from traditional ones that have been used for centuries to recently designed ones relying on new manufacturing technologies, studies of performance under extreme service conditions provide an indispensable basis for their applications in a wide variety of fields, such as defense-related and astronautics industries,1–5 the nuclear industry,6–13 and nano-manufacturing.14,15 In this context, the mechanical responses of ductile metals under high-strain-rate loading conditions are of great interest, including their dynamic yielding behavior and dynamic fracture process. The fundamental mechanism governing the dynamic fracture of ductile metals has been widely studied, especially in recent years, since it not only provides a basis for further theoretical studies of the mechanical behavior of these materials, but is also very different from the mechanism of fracture in quasistatic conditions.
Spalling is one of the most important dynamic fracture modes in metals, and observations of spalling using relatively simple experimental methods can reveal fundamental mechanical aspects of the dynamic fracture process.1 The spalling process can be described as follows. A sufficiently energetic strike resulting from plate impact, explosive detonation, or laser shock will first produce shock compression pulses, which are then transformed into rarefaction waves after free-surface reflection. The interference between these rarefaction waves produces a state of high tensile stress in the target, causing planar separation of material. Spalling in brittle metals is characterized by cracks with sharp tips around which little plastic deformation takes place, whereas in ductile metals, it is characterized by voids that tend to be spherical up to a certain size.1 From a microscopic point of view, the spalling in ductile metals results from nucleation, growth, and coalescence of these voids.16 In the past few decades, an abundance of experimental and computational studies have helped to reveal a wealth of information about the nucleation and growth process from microscopic to macroscopic aspects.1–4 On the one hand, these studies have provided increasingly clear physical pictures, on the basis of which we have come to understand the underlying mechanism of the damage initiation process and describe this process in precise mathematical terms. On the other hand, the development of experimental and simulation techniques in this field has led to a need for a powerful and effective theory to describe current observations and to provide a reliable reference for further investigations. For instance, a theoretical model that could accurately predict the critical nucleation stress would be very helpful if the appropriate velocity of the flyer needed to be set in a plane impact experiment to cause only incipient damage to the target. To sum up, the study of theoretical models helps to reveal the mechanism of void nucleation and growth under dynamic loading and makes an important contribution to the design of damage-resistant materials. Therefore, in this review, we summarize classical work and recent research progress on theoretical models related to void nucleation and growth under dynamic loading.
The remainder of the paper is organized as follows. In Secs. II and III, theoretical works on void nucleation and growth, respectively, are introduced, with the former covering models of void nucleation from common crystallographic defects and the latter dealing with growth models based on classical and on newly developed constitutive relations. A summary and outlook are presented in Sec. IV.
II. MODEL OF VOID NUCLEATION
Since the stages of void nucleation and growth are usually coupled with each other, the definition of nucleation remains controversial among researchers owing to different perspectives that they adopt. Specific definitions of void nucleation are basically of two types (1) size-based and (2) process-based.
From a size-based perspective, Curran et al.17 defined the nucleation of microscopic fracture as the appearance of microscopic flaws (or voids) whose sizes are comparable to the size of the continuum limit of the material. However, this definition inevitably also includes submicroscopic growth in the vast majority of cases. From a process-based perspective, nucleation is defined as the creation of a flaw (or a void) large enough to grow under an applied stress field.18,19
For nucleation occurring at the microscale, the above two definitions are often equivalent to each other. For nucleation at the nanoscale, however, a size-based definition may lead to an inaccurate division of the stages involved. Although they recognized the theoretical attraction of the process-based definition, Curran et al.17 held the view that the difficulty of applying continuum mechanics to describe events at a scale much smaller than the continuum limit hinders its adoption. This point of view was reasonable, considering the experimental techniques available at that time, but subsequent technical developments have made it somewhat outdated. Recently, extensive experiments and simulations have focused on nanoscale nucleation, and the abundant information that these have provided has now revealed the physical mechanisms of nanoscale nucleation, making it feasible to model some of these mechanisms in the framework of continuum mechanics.20,21
In this section, we overview the microscopic mechanisms of void nucleation under dynamic loading, which can be classified into two categories: heterogeneous and homogeneous nucleation.1,22 Heterogeneous nucleation usually occurs at micrometer-sized defect sites such as grain boundaries, triple junctions, and second-phase particles. Homogeneous nucleation, as suggested by previous studies,1,19,22 refers to the nucleation process originating at perfect lattice structures or submicroscopic heterogeneities within grains. Besides the nucleation mechanism, the size distribution and statistical evolution of the nucleated voids are also important issues in this field. The associated models are covered in previous comprehensive reviews3,23 and are not discussed in this paper.
A. Models of heterogeneous void nucleation
Deformation around inclusions and second-phase particles is an important mechanism for void nucleation under dynamic loading. As experimental evidence for this, Pedrazas et al.25 presented the strong correlation between second-phase particles and the dimples produced in spallation at very high strain rates [∼(2–4) × 106 s−1], even for commercially pure aluminum (99%). The nucleation mechanism of inclusions and second-phase particles includes cracking of inclusions, debonding at interfaces, and matrix fracture near inclusions.1,17 Models of void nucleation in material containing a dispersion of inclusions or second-phase particles have been proposed in the past few decades to predict the onset of damage initiation. For void nucleation at the matrix–particle interface, there are two necessary conditions for the void nucleation process, namely, the mechanical debonding condition and the energetically favorable condition.17
The mechanical debonding condition of the nucleation process was analyzed by Ashby24 based on a stress calculation, and it was found that nucleation occurs when the tensile stress along the tensile axis (which may result from the applied tensile stress along
Figure 1.Nucleation occurs at the matrix–particle interface owing to tensile stress.
Tanaka et al.26 analyzed the critical strains that satisfy the stress condition and the energy condition, respectively. The critical strain that corresponds to the stress condition26
Figure 2.Critical strain of void nucleation at particles.
Based on the deformation incompatibility between the hard particles and the matrix, a modified model was proposed from a different perspective.27,32 The stress condition of the model in Goods and Brown27 accounted for the influence of particle size through the work-hardening effect of the inclusion. The local flow stress was derived as
Figure 3.Schematic of void nucleation at a particle. Separation occurs at the poles of the particle.
In summary, there are two necessary conditions for void nucleation at inclusions, namely, the mechanical debonding condition and the energetically favorable condition. The dependence on particle size varies from r−1/2 through no dependence to r owing to the different assumptions adopted in the models. It is worth mentioning that although the above models are based on quasistatic analyses, the feasibility of applying them to the dynamic loading condition has been proved.17
Besides inclusions and second-phase particles, grain boundaries are also important heterogeneous nucleation sites. For void nucleation on the grain boundary, only the energetically favorable condition needs to be satisfied, i.e., the external work done on an element containing a virtually growing void must exceed the energy required to create the surface of the new void.17,18 The critical condition is expressed as
B. Models of homogeneous void nucleation
In contrast to alloys and high-purity polycrystalline metals, few pre-existing nucleation sites are available for high-purity monocrystalline metals under high-strain-rate loading. Dislocation networks and vacancy clusters generated during the deformation process serve as potential nucleation sites for the homogeneous nucleation process in this kind of material. In this section, models related to the vacancy-mediated nanovoid nucleation mechanism are introduced in detail.
The void nucleation stage begins after the shock wave has propagated in the interior of the sample. Vacancy clusters generated by diffusion-mediated aggregation are potential nucleation sites that may finally evolve into macroscopic voids and lead to fracture. As suggested by Reina et al.,19 the “already nucleated” state of a potential nucleation site corresponds to the onset of plastic cavitation, i.e., the formation of vacancy clusters of a size such that subsequent growth can happen by plasticity. Therefore, the triggering of plastic cavitation can be regarded as the criterion for void nucleation.19 It should be emphasized that the emission of dislocation loops is the mechanism of plastic cavitation under high-strain-rate loading, which is different from the quasistatic case and has been confirmed by experiments and simulations.42–49 In the case of quasistatic loading, plastic cavitation can occur by a vacancy-diffusion-based mechanism, i.e., vacancy condensation under an external stress field or elevated temperature.23,50 However, the time available for vacancy diffusion under shock loading is very limited and is far less than the time required for a diffusion-based cavitation mechanism.20,51 Previous studies have focused on the external stress required to trigger dislocation emission on void surfaces in the interior of ductile metals. The so-called critical emission stress has been simulated in different metals and under different loading conditions.43,46–49 Theoretical models have also been proposed to analyze the emission process and derive a stress-based emission criterion.
Two-dimensional (2D) elasticity theory is adopted to develop the emission criteria from scratch. An explicit expression for the critical emission stress was first proposed by Lubarda et al.20 The first step in establishing the emission criterion is to derive the total glide force actingon the dislocation. This is obtained as
Figure 4.(a) 2D configuration of dislocation emission. (b) Stress state at the point of dislocation due to equal biaxial tension
Figure 5.Normalized critical emission stress vs normalized radius of void. The three curves represent three different dislocation widths:
However, there are several drawbacks in their model. First, it assumes that the dislocation is emitted from the void surface along the direction of the maximum shear stress under biaxial equal tension.20 The emission direction (i.e., the rotation angle of the slip plane relative to the radial direction) is not taken as variable. Therefore, their model cannot account for the finite number of slip systems available in real materials, which limits its range of application. Second, effects resulting from the existence of other voids cannot be investigated. The void in their model is assumed to be in an ideal elastic medium, whereas actual void nucleation and growth process take place in solids with dispersed voids.
A revised dislocation emission model taking account of the emission direction was proposed by Lubarda.52 Two related sets of polar coordinates (ρ, θ) and (r, φ) were adopted to locate the position of the dislocation relative to a point on the void surface and the center of the void, respectively. The total glide force under biaxial equal tension was derived as
To consider the influence of other voids, a criterion for dislocation emission in porous solids was proposed by Wilkerson and Ramesh.21 In their work, an auxiliary problem that is simple enough for closed-form solutions to be derived was constructed from the original one. The dislocation emission from a spherical void in a porous material under a general 3D macroscopic stress state was simplified to a 2D problem in which dislocation emission from an infinitely extended cylindrical void occurs in an infinite isotropic linear-elastic medium. Dislocation emission was proved to occur more easily with increasing porosity in their model.
The 2D criteria lay the foundation for a theoretical description of dislocation emission. However, these models based on a 2D configuration introduce an excess of assumptions. These assumptions help in the derivation of closed-form solutions that are as simple as possible, but they also leave out some important information. First, the real physical process of dislocation emission, namely, the emission of 3D dislocation loops,43,54–59 is overly simplified in 2D configurations. Second, the influence of some important factors in the actual 3D process, such as the actual porosity or the actual stress triaxiality, cannot be investigated directly in 2D configurations. Owing to the dimensionality reduction, further hypotheses must be introduced in 2D models. For example, the original 3D macroscopic stress is approximated as an effective 2D stress state,21 while dispersed spherical voids are approximated as arrays of cylindrical voids to derive an effective porosity.21
Pioneering work on the mechanical description of 3D dislocation loops was done by Willis and Bullough,60 who analyzed the interaction between a spherical void and a circular interstitial dislocation loop using spherical harmonics. On this basis, Ahn et al.61,62 proposed the concept of a threshold applied stress for the emission of prismatic dislocation loop (PDL) in an ideal elastic material under hydrostatic loading. However, the accuracy of their model is limited by the hypotheses required and the use of artificially introduced parameters. Besides, some important factors were not been included in their model, such as emission position, porous softening, and stress triaxiality.
Recently, a 3D criterion in porous media has been proposed to determine the critical emission stress of a PDL, σcr, and the corresponding emission angle θcr specifying the emission position on the spherical void surface,53 as illustrated in Fig. 6. Based on this model, Sui et al.53 systematically studied the factors influencing PDL emission in a 3D configuration, such as the geometric parameters, the stress triaxiality, and the porosity. The criterion for dislocation was derived as
Figure 6.3D configuration of dislocation emission. Variables with subscript 0 are geometric parameters associated with the prismatic dislocation loop (PDL).
Figure 7.Effect of porosity
Figure 8.Effect of stress triaxiality on dislocation emission.
III. MODELS OF VOID GROWTH
Void growth is vital for the evolution of ductile damage and dramatically influences the service life and performance of materials. In this section, phenomenological and physics-based growth models are introduced. Phenomenological models adopt the traditional constitutive relationships to describe the dynamic growth process of a void, while physics-based models describe the same process by focusing on the laws governing the evolution of microstructures under high-strain-rate loading conditions.
A. Phenomenological growth models
It is worth mentioning that quasistatic void growth models provide the basis for the dynamic ones. The earliest models describing the growth of isolated voids in ductile metals under quasistatic loading conditions were first developed in the last century.63–68 Since these models cannot capture the important effect of an evolving void volume fraction in actual situations, the micromechanics-based Gurson model69 and its modifications were subsequently proposed to consider the influence of void interactions. The development of dynamic growth models is closely related to that of quasi-static models. In this section, phenomenological dynamic growth models are systematically introduced. We start from the dynamic growth of an isolated void in an infinite medium as the basis for the following models. Subsequently, statistically based models and micromechanics-based models that describe the macroscopic mechanical response of the damaged material are introduced.
1. Dynamic growth model of isolated void
The dynamic growth of a single void in a power-law-hardening unbounded solid was studied by Ortiz and Molinari,70 who systematically investigated the effects of inertia, strain hardening, and rate dependence under conditions of high-strain-rate loading from an energetic viewpoint. They assumed the matrix to be incompressible and the void to remain spherical during the process of growth. Based on the principle of conservation of energy, the evolution laws of the void radius for both the rate-dependent [Eq. (19a)] and rate-independent [Eq. (19b)] cases were derived as follows:
Taking the influence of heat conduction into consideration, Wu et al.71–73 proposed a thermal–mechanical coupling model to study the dynamic growth of a single spherical void, with special attention being paid to the comprehensive effect of inertia, thermal softening, rate dependence, and plastic strain gradient. The evolution law of the void in their work was derived as
2. Growth model coupled with statistical theory
The evolution law for an isolated void in an infinite plastic matrix71 was adopted by Molinari and Wright74 to propose a statistical description of damage evolution. Equation (23) is rewritten as
3. Gurson-type model with dynamic correction
The studies described in Sec. III A 1 focused on the dynamic response of a single void in an elastoplastic matrix. These are highly conducive to investigations of the influence of different factors during the process of void growth, but they cannot be used as a basis for studying the macroscopic mechanical response of a material under dynamic loading, which requires a different perspective.
Gurson69 was the first to propose approximate yield criteria and flow rules for ductile porous materials in a micromechanics-based framework, with the matrix material being idealized as rigid–perfectly plastic and obeying the von Mises yield criterion. The yield function was derived as
Because the rigid–perfectly plastic assumption69 is too strict to be satisfied by the majority of materials, extensions have been proposed to study more complex constitutive behaviors and geometric configurations, such as viscoplastic effects,82,83 plastic anisotropy,84–86 crystal plasticity,87,88 and void shape effects.89 The most important modification of the Gurson model is the Gurson–Tvergaard–Needleman (GTN) model,90–92 which provides a mixed phenomenological and micromechanics-based framework to precisely describe the whole fracture process of a porous medium. The yield condition is expressed as
The Gurson model has also been used to deal with the dynamic failure of ductile materials. A Gurson-type model has been directly applied to dynamic ductile fracture93–95 and dynamic crack growth.96–98 Since the inertial effects are not considered in the original form of the Gurson model, further modification is necessary for the situation of dynamic loading.99 Similar to the original form in Eq. (34), a dynamic correction of the Gurson model was derived by Wang and Jiang99 based on the principle of virtual work:
Although the expression for the macroscopic stress includes both static and dynamic contributions, Molinari and Mercier101 held the view that the definition of the macroscopic stress in previous works99,100 was still a “static” one, i.e., the average value of the microscopic stress was given by
Under the assumption that the deviatoric stress components are negligible when a large hydrostatic pressure is generated in the metallic plates during plane impact, Eq. (39) was rewritten by Czarnota et al.75 as
It should be emphasized that Eq. (40) is the governing equation of the hollow sphere configuration. Taking the hollow sphere model as the microscopic unit cell, different homogenization methods are used to link the macroscopic quantities defined at the remote boundary of the material domain to the microscopic ones defined at the unit cell level.76,78 Czarnota et al.76 extended Eq. (40) to account for an elastic–viscoplastic material response and implemented this extension in ABAQUS/Explicit software to simulate plate impact experiments, and the results reproduced experimentally measured free-surface velocity profiles with excellent accuracy (Fig. 9). Jacques et al.78 used a different homogenization scheme to simulate crack growth in a notched bar and in an edge-cracked specimen. It was revealed that the effects of micro-inertia lead to lower crack speed and higher dynamic fracture toughness (Fig. 10).
Figure 9.Simulated free-surface velocity profiles. Two strategies of homogenization modeling are adopted: the p-model assumes that a uniform pressure is applied to all unit cells, while the d-model assumes that a uniform strain rate is prescribed on unit cells. For more details, see Czarnota
Figure 10.J-resistance curves for the growth of a ductile crack.
B. Physics-based growth model
The growth models described in Sec. III A are based on traditional plastic constitutive relationships and vary from simple models (e.g., the rigid–perfectly plastic model) to complex ones (e.g., the thermal–mechanical coupled power-law-type rate-sensitivity model). However, these models may become invalid at extreme strain rates, i.e., ≥108/s, since there is a dramatic transition in the strain rate dependence of the spall according to the summary presented by Reina et al.19 (Fig. 11). Therefore, phenomenological growth models are perhaps only applicable in the thermally activated glide regime, and a dislocation-based viscoplasticity constitutive relation that accounts for drag and relativistic effects is needed in the case of extreme loading conditions.83
Figure 11.Influence of strain rate on spall strength for aluminum samples with different purity.
A dislocation-based viscoplasticity model applicable at very high strain rates was first proposed by Austin and McDowell.82 Based on J2 flow theory with isotropic hardening, the plastic deformation rate is written as
Figure 12.Material velocity profiles for different shock stress amplitudes.
Starting from the dislocation-based J2 theory of Austin and McDowell,82 Wilkerson and Ramesh111 developed a micromechanics-based model to describe the void growth rate, taking account of the effects of micro-inertia, dislocation kinetics, and substructure evolution. The RVE in their work was still taken as the classical spherical shell model, in which a spherical void of radius a is embedded in a sphere of radius r0 (with the inner and external radii of the spherical shell in the reference configuration being denoted by A and R, respectively). Based on the assumptions that the plastic deformation is incompressible and that the elastic deformation rate is negligible, the strain rate of a material element located at
It should emphasized that physics-based growth models have undergone rapid development in the past decade.83,112–115 The use of dislocation-based J2 theory to describe the dynamic response of materials under extreme strain rates has been further extended to dislocation-based crystal plasticity by Lloyd et al.112 and Luscher et al.113 On this basis, the theory of dynamic void growth in single crystals under extreme loading has been developed by Nguyen et al.114,115 to describe the growth process under general loading states, since their previous physics-based model is only suitable for a pure hydrostatic loading state.111 Much effort has been also been spent on modifying the description of the evolution of dislocation substructures to obtain a closed-form approximation of the governing differential equations, and on implementing the constitutive relation in finite element methods to simulate experimental results.83,113–115
IV. SUMMARY AND OUTLOOK
This review has provided a summary of theoretical research on void nucleation and growth in ductile metals under dynamic loading. Both the macroscopic mechanical response and the microscopic physical mechanism, as the two most important aspects, have been investigated over the past few decades. Much theoretical works has been done to clarify the underlying mechanisms of damage initiation and evolution and to provide increasingly precise descriptions of these mechanisms. However, there is still a long way to go to before a complete framework describing ductile damage initiation under extreme dynamic loading is established.
First, with regard to dynamic void nucleation at complex microstructures, such as grain boundaries, grain boundary triple junctions, and the dislocation cells, the currently available physics-based theoretical models suffer from deficiencies arising from the combined effects of the complex nature of the stress state and the irregular geometric configuration. With future experiments likely to provide more detailed information, related theoretical models are expected to be developed and to help in investigating the laws of evolution and the key factors involved in these process.
Second, it is important but challenging to extend the study of traditional ductile metals to newly developed metallic materials that have good performance and wide prospects for application, such as nanocrystalline materials and high-entropy alloys. The processes involved in dynamic damage of such materials under high-strain-rate loading conditions cannot straightforwardly be predicted on the basis of existing knowledge about traditional metals, since the fundamental damage mechanisms can be quite different. Therefore, combined experimental, computational, and theoretical efforts are needed to investigate the mechanism of damage initiation and evolution of these new materials.
Finally, the study of ductile damage initiation and evolution covers spatial scales from nanometers to millimeters and temporal scales from picoseconds to microseconds. Therefore, it is a great challenge to establish a multiscale theoretical framework to bridge the microscopic physical mechanism and the macroscopic mechanical response. In addition, given the spatial and temporal resolutions required to monitor the variation of microstructures, more advanced experimental and simulation techniques are needed to accurately determine the related information. Such techniques should reduce the number of phenomenological parameters that need to be used in the multiscale theoretical framework and thereby allow a more precise description of the fracture process.
ACKNOWLEDGMENTS
Acknowledgment. Financial support for this work was provided by the Science Challenge Project (Grant No. TZ2018001) and the National Natural Science Foundation of China (Grant Nos. 11988102, 11632001, 11521202, and 12002005).
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