Rapid Quantification of Dynamic and Spall Strength of Metals Across Strain Rates

Abstract

The response of metals and their microstructures under extreme dynamic conditions can be markedly different from that under quasistatic conditions. Traditionally, high strain rates and shock stresses are measured using cumbersome and expensive methods such as the Kolsky bar or large spall experiments. These methods are low throughput and do not facilitate high-fidelity microstructure-property linkages. In this work, we combine two powerful small-scale testing methods, custom nanoindentation, and laser-driven micro-flyer shock, to measure the dynamic and spall strength of metals. The nanoindentation system is configured to test samples from quasistatic to dynamic strain rate regimes (10$^{-3}$ s$^{-1}$ to 10$^{+4}$ s$^{-1}$). The laser-driven micro-flyer shock system can test samples through impact loading between 10$^{+5}$ s$^{-1}$ to 10$^{+7}$ s$^{-1}$ strain rates, triggering spall failure. The model material used for testing is Magnesium alloys, which are lightweight, possess high-specific strengths and have historically been challenging to design and strengthen due to their mechanical anisotropy. Here, we modulate their microstructure by adding or removing precipitates to demonstrate interesting upticks in strain rate sensitivity and evolution of dynamic strength. At high shock loading rates, we unravel an interesting paradigm where the spall strength of these materials converges, but the failure mechanisms are markedly different. Peak aging, considered to be a standard method to strengthen metallic alloys, causes catastrophic failure, faring much worse than solutionized alloys. Our high throughput testing framework not only quantifies strength but also teases out unexplored failure mechanisms at extreme strain rates, providing valuable insights for the rapid design and improvement of metals for extreme environments.