Research progress on impact energy release characteristics of reactive disordered alloy and its application in kill elements
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摘要: 无序合金是一种新型金属材料,突破了传统的合金设计理念,表现出不同于传统合金的优异力学性能、冲击释能及剪切自锐特性,在高温、高压、高应变率等环境具有良好的应用前景。分析活性无序合金的冲击释能特性对其应用于军事领域有着重要的指导作用,能为弹药战斗部的设计提供参考。本文阐述了静动态力学实验中典型无序合金的反应释能现象;总结了撞击速度与活性无序合金释能超压、释能效率之间的关系;讨论了撞击速度、材料破碎程度及靶标特征等因素对活性无序合金释能机理的影响;归纳了制备工艺及元素类型对活性无序合金释能特性的调控效果。进一步,本文梳理了活性无序合金在破片、穿甲弹芯和聚能装药战斗部三个方向的应用研究进展,分析了活性无序合金毁伤元的侵彻行为和作用机制。最后,针对活性无序合金材料未来的发展趋势和需求进行了展望。Abstract: Disordered alloy is a new kind of reactive material, which breaks through the design concept of traditional alloy and exhibits excellent mechanical properties, impact energy release characteristics and adiabatic shear sensitivity, showing good application prospects in high temperature, high pressure, high strain rates and other application environments. Analyzing the impact energy release characteristics of reactive disordered alloy has an important guiding role for its development in the military field and can provide the basis for the design and application of warheads for ammunition. In this paper, the impact energy release characteristics of reactive disordered alloys are introduced from four aspects, including the energy release phenomenon of chemical reaction, the energy release law induced by impacting, the energy release mechanism and the regulation of the energy release behaviors. The chemical reaction showing energy release phenomenon in static and dynamic mechanical experiments is described. The relationship between impact velocities and the energy release overpressures or the efficiency of energy release of reactive disordered alloys is obtained. The effect between impact velocities and crushing degree of the reactive disordered alloys or characteristics of the target on the energy release mechanism is discussed. At the same time, the regulation effects of preparation process and the kinds of element on energy release effect of disordered alloy materials are summarized. This kind of alloy own good impact energy release characteristics, presented an ideal energetic structural material. Furthermore, the research progress of reactive disordered alloys applied to warheads in military area is summarized from three directions, including fragment, armor-piercing core and shaped charge liner. The macro and micro penetration behavior and mechanism of warheads of reactive disordered alloys are analyzed under high-speed loading conditions. Via the design of the structure, the good penetration and damage performance benefit from the self-sharpening and energy release characteristics of the material. Finally, the further development trend and demands of reactive disordered alloy are prospected.
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纺织结构复合材料是以纺织纤维体作为增强材料,用树脂固化后形成的纤维增强复合材料。二维纺织结构主要包括平纹、斜纹和缎纹织物,具有比强度高、比刚度大和材料性能可以设计等优点,在防护工程领域具有良好的应用前景[1]。P.M.Cunniff[2-3]研究了子弹侵彻叠层平纹织物时的入射速度和剩余速度的关系,得到了在不同形状子弹侵彻下结构的弹道极限以及半经验公式;顾冰芳等[4]研究了不同形状子弹冲击下Kevlar纤维叠层织物的防弹机理和性能,观测了纤维的表观破坏形态和微观损伤机理;R.Barauskas等[5]基于LS-DYNA软件通过考虑纱线滑动、子弹和纱线之间的滑动计算了二维编织物在可变形体侵彻下的破坏过程。这些研究主要关注纤维材料的弹道冲击侵彻性能,而对于复合材料整体动力响应方面的研究还较少。V.Kostopoulos等[6]使用有限元技术分析了3种不同的复合材料(碳、玻璃和Kevlar)制作的摩托车安全头盔的冲击动态响应过程,发现Kevlar配置的安全头盔防护性能要优于其他2种,指出Kevlar较低的抗剪性增强了头盔的能量吸收和压缩能力。I.Taraghi等[7]研究了常温(27 ℃)和低温(-40 ℃)下,多壁碳纳米管增强的平纹Kevlar/环氧树脂复合板的低速冲击响应,在基体内加入一定量的多壁碳纳米管能显著提高复合板的吸能和刚度。P.N.B.Reis等[8]研究了Kevlar/纳米粘土增强环氧树脂复合板的冲击响应,通过在基质内加入一定量的纳米粘土可以提高复合板的弹性恢复性能和侵彻阀值。本文中研究了钢制平头弹撞击下平纹Kevlar纤维复合板的动态响应,给出了复合板的变形失效模式。在实验的基础上,利用LS-DYNA分析钢质平头弹冲击载荷作用下平纹Kevlar纤维复合板的动力响应和纤维铺层数对结构动力响应的影响,模拟结果与实验吻合较好。
1. 实验
1.1 实验过程
实验试件为编织Kevlar/Epoxy复合材料层合板,尺寸为300 mm×300 mm。试件铺层厚度0.27 mm,共18层,经浸渍环氧树脂后加温加压形成。每层织物组织都为平纹组织,由2根经纱和2根纬纱组成织物循环,经纱和纬纱每隔1根纱线交织1次。实验采用平头钢制子弹,长度150 mm,直径为37 mm,质量为1.24 kg。冲击实验装置由空气动力枪、激光位移传感器(micro-epsilon LD1625-200,响应特性:采样率37 kHz,每秒采集185 000个点,能够实时探测到靶板中点的位移)、激光测速仪、实验夹具、超动态应变仪和高速摄像机等组成,如图 1所示。实验加载是通过空气动力枪驱动钢制子弹撞击复合板实现,子弹速度由空气动力枪气压控制,其大小由激光测速装置获得。实验支架采用钢制正方形夹具,端面平整,其外部边长400 mm,内部边长250 mm,通过螺栓固定在不可移动的平台上。实验中通过高速摄像仪对整个加载过程进行了拍摄。
1.2 实验结果
分别对试件的变形失效模式和背面中心点的挠度进行分析,实验结果如表 1所示,n为层数,h为纤维复合板的厚度,v为冲击速度,I为冲击冲量,W为残余挠度。结构在冲击载荷下主要呈现3种变形失效模式:Ⅰ型为未发生明显破坏失效,整体呈现弹性变形,如图 2(a)所示;Ⅱ型为复合板表面子弹作用区域的嵌入失效,结构呈整体塑性大变形,如图 2(b)所示;Ⅲ型为背面纤维拉伸断裂及分层失效,如图 2(c)所示。
表 1 实验数据Table 1. Experimental dataNo. n h/mm v/(m·s-1) I/(N·s) W/mm 变形失效模式 1 18 5.11 13.30 16.49 1.8 Ⅰ 2 18 4.98 24.70 30.63 8.3 Ⅱ 3 18 5.15 32.60 40.42 12.4 Ⅱ Ⅲ 4 18 5.13 36.47 45.22 13.5 Ⅱ Ⅲ 5 18 5.10 36.50 45.26 13.3 Ⅱ Ⅲ 平头弹撞击瞬间,复合板受载边界处将产生较大的剪切应力,导致表面纤维及胶层瞬时剪切失效,因此正面受冲击区域边缘发生了明显的嵌入失效;纤维良好的延展性使得复合板整体为塑性大变形,呈现穹形;纤维的正交分布导致背面纤维拉伸断裂后裂纹沿着垂直于断裂纤维方向扩展,并且出现了分层现象,因此背面发生近似方形的局部破坏(不考虑夹具的影响)。
从表 1中看出,在不同冲击速度下,复合板背面中心点的残余挠度随着冲击速度的增加逐渐增大。图 3给出了不同冲击速度下复合板背面中心点的挠度时程曲线,可以看出:在子弹冲击作用下,板背面中心点在0.8 ms左右达到最大挠度,随后发生反弹,在平衡位置附近进行振荡,最终静止;且当冲击速度v=13.30 m/s时,试件的后面板的瞬时挠度峰值是最终挠度的5.7倍,即后面板瞬时挠度有可能对被保护的人员或结构产生更大的伤害,因此在用作防护结构时不能仅考虑最终挠度。
2. 数值模拟
2.1 有限元模型
2.1.1 材料参数
纤维层采用复合材料平纹织物层合板模型(MAT_LAMINATED_COMPOSITE_FABRIC)具体材料参数见表 2,其中ρ为密度,E为弹性模量,Gab为面内剪切模量,Gca为层间剪切模量,ν为泊松比,Xt为纵向拉伸强度,Xc为纵向压缩强度,Yt为横向拉伸强度,Yc为横向压缩强度,Sc为面内剪切强度。环氧树脂层采用双线性应变强化弹塑性模型,密度为1 200 kg/m3,弹性模量为12.0 GPa,泊松比为0.34。假定冲击过程中子弹和夹具没有变形,采用刚体模型,密度为7 800 kg/m3。
表 2 Kevlar纤维平纹织物的材料参数Table 2. Material properties of the Kevlar composite fabricρ/(kg·m-3) E/GPa Gab/GPa Gca/GPa ν Xt/GPa Xc/GPa Yt/GPa Yc/GPa Sc/GPa 1 400 59.5 5.18 5.18 0.34 1.20 0.23 1.20 0.23 0.12 2.1.2 几何模型
图 4给出了Kevlar/Epoxy复合材料层合板在冲击载荷作用下的数值分析模型及冲击实验照片。为了实现与实验尽量一致的边界,数值模拟中同样采用了实验中的夹具形式:夹具与复合板之间定义自动面对面接触;子弹与纤维层、胶层之间定义侵蚀接触;纤维层与胶层之间共节点连接;在螺栓位置,采用弹簧单元来模拟夹具中螺栓的紧固作用。复合板为300 mm×300 mm的正方形,有效面积为250 mm×250 mm。基于LS-DYNA软件,建立了1/4计算模型。纤维层采用shell193壳单元,单元尺寸为1.875 mm×1.875 mm,每层厚度为0.27 mm。上下表面及纤维层之间建立环氧树脂层,环氧树脂层采用solid164实体单元,单元尺寸为1.875 mm×1.875 mm×0.27 mm。子弹同样采用solid164实体单元。整个模型中,纤维分为18层,共115 200个单元,胶层分为19层,共121 600个单元,经过网格敏感性验证,所选网格比较稳定,可以满足计算需要。
2.2 数值模拟验证
图 5给出了冲击速度v=36.47 m/s时,Kevlar纤维复合板受撞击变形的实验与数值模拟对比。复合板整体为塑性大变形,呈现穹形,中心受子弹冲击区域挠度最大,向边界处逐渐减小。正面子弹冲击区域边缘发生了明显的嵌入失效;背面纤维断裂呈现近似方形的破坏。表 3给出了复合板受冲击最大位移、冲击后残余挠度的模拟结果与实验结果的对比。可以看出Kevlar/Epoxy复合材料层合板的变形失效模式、残余挠度的数值模拟结果和实验结果吻合较好,误差均在20%以内。由此可见,本文中建立的有限元模型是可靠的,可以用于进一步的Kevlar纤维复合板抗冲击性能的分析。
表 3 Kevlar纤维复合板在不同速度冲击下实验与数值模拟对比Table 3. Comparison of the experimental and simulated results at different impact velocitiesv/(m·s-1) dmax/mm W/mm 实验 数值模拟 ε/% 实验 数值模拟 ε/% 13.30 10.3 9.3 -9.71 1.8 1.5 -16.67 24.70 14.2 14.8 4.23 8.7 7.9 -9.20 32.60 18.3 17.6 -3.83 12.4 11.2 -9.68 36.47 20.7 20.3 -1.93 13.5 13.6 0.71 36.50 19.9 20.3 2.01 13.3 13.6 2.21 3. 结果分析
3.1 动态响应过程
图 6给出了冲击速度v=36.47 m/s下子弹和复合板的相互作用过程,整个过程可以分为2个阶段。(1)加载阶段(0≤t≤1.1 ms):子弹发射后高速冲击复合板,板面受冲击后与子弹具有相同的速度一起运动,变形区域从中心向边界处传播,出现穹形大变形;t=0.8 ms后随着变形进一步增加,冲击区域环氧树脂发生失效破坏结构中点挠度进一步增加;t=1.1 ms后背面纤维拉伸断裂,结构中点挠度达到最大值。(2)卸载阶段(t>1.1 ms):结构贮存的弹性应变能转化为板和子弹的动能从而发生反向回弹, 结构与子弹以相同的速度开始反弹,t=2.0 ms结构与子弹分离,t=2.2 ms结构反弹至反向最大挠度后进入自由振动阶段,并最终静止。如图 4(a)所示,在复合板背面纤维单元上分别取7个测点,其中1#点位于板中心,3#点位于距离中心点18.5 mm处(即子弹边缘与板面的交界处),7#点位于边界处。图 7(a)给出了1#、3#、5#和7#点的x方向的应力时程曲线,可以看出7#点(边界处)应力正负交替出现,说明复合板在边界处沿x方向发生了弯曲变形;加载区域内纤维的应力要高于加载区域外,且加载区域边界处的应力最大,因而更容易发生纤维的拉伸断裂。图 7(b)给出了3#点截面处沿厚度方向第1、7、11和18层纤维单元x方向的应力分布,可以看出复合板所受应力由压应力逐渐转变为拉应力。因此,复合板首先在3#点截面第18层纤维单元处发生拉伸破坏。
3.2 参数分析
为了研究加载冲量及铺层数对结构响应的影响,分别计算了不同加载冲量下(12.4~47.12 N·s),不同铺层数(6、9、12、15和18层)的复合板的动态响应:分别从复合板的能量吸收规律和背面中心点的残余挠度进行了研究。研究表明复合材料层合板的抗冲击性能与其铺层数和外加载荷有密切的关系。分别将纤维复合板的残余挠度W、初始冲量I以及能量吸收Ea按下面的方法量纲一化:
ˉW=Wh,ˉI=Im′√σyρ,m′=ms,ˉE=EaEi 式中:ρ纤维的密度,m为纤维复合板的质量,s为纤维复合板的有效作用面积, σy为屈服应力,Ei为子弹的冲击能量。
Kevlar纤维复合材料层合板用于工程防护结构时,一般将其背面的残余变形作为抗冲击性能的主要参数。图 8给出了铺层数不同的复合板背面中心点量纲一残余挠度随量纲一冲量变化的规律,可以看出:铺层数相同的复合板背面中心点的残余挠度随着冲量的增大逐渐增大;当I=0.8时,12层的复合板挠度最小,表现出最好的抗冲击性能;I≤0.75时,15和18层的复合板挠度差异很小;当I>0.8时,18层的复合板挠度最小。因此在本文中研究的冲量范围内,随着冲量的变化,并不是纤维层数越多,复合板的挠度越小。
冲击能量Ei代表了结构可以转化的最大能量即子弹的动能,反之吸收能量Ea为结构实际转化的能量。从图 9可以看出,纤维复合板的吸能效率E随着加载冲量和复合板铺层数的增加逐渐增大。冲量相同的情况下,吸能效率的提高随铺层数的增加呈现递减趋势;当I>0.6时,15和18层铺层的复合板的吸能效率差异很小。虚线对应的点的横坐标为各结构发生侵彻破坏的阀值。
4. 结论
针对Kevlar/Epoxy复合材料层合板在钢制平头弹冲击下的动态响应开展了实验研究和数值模拟,分析了结构在不同冲量下的变形失效模式以及抗冲击性能,主要结论如下:
(1) 编织Kevlar纤维层合板的冲击失效模式与结构配置和载荷强度有关,主要表现为弹性变形、复合板表面嵌入失效及整体塑性大变形和背面纤维拉伸断裂及分层失效。
(2) 数值模拟表明,子弹撞击区域边界处纤维应力沿厚度方向由压应力逐渐变为拉应力,且最大拉伸应力出现在背面几层。
(3) 在一定的冲量范围内,数值模拟结果表明复合板的动力响应与铺层数和加载冲量密切相关;通过对复合板铺层数的优化,能够有效地减小后面板挠度,提高结构的能量吸收效率,增强结构的抗冲击性能。
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图 63 射流侵彻后靶板的EBSD细观分析:(a)变形区IPF图;(a)中区域b的(b1、b2)IPF图和对应的KAM图;(a)中区域c的(c1, c2) IPF图和对应的KAM图[113]
Figure 63. Microstructural analysis of the residual jet after penetration via EBSD: (a) IPF map of deformation zone; (b1, b2) IPF map and corresponding KAM map of region b in (a); (c1, c2) IPF map and corresponding KAM map of region c in (a)[113]
图 64 再结晶区的高倍BSE-SEM图像(a)及线扫描分析(b):在(a)中显示的两个晶界上进行线扫描,其对应的位置在(b)中用虚线标记[113]
Figure 64. High-magnification BSE-SEM images (a) and line scan analysis (b) of the recrystallization region: a line scan was conducted across two grain boundaries as displayed in (a), the corresponding locations of which are labeled with dashed lines in (b)[113]
图 65 CoCrNi残余射流侵彻后的TEM组织分析:(a) CoCrNi残余射流的TEM照片,其中的白色虚线标记了沿晶界的纳米尺寸沉淀;(b) 降水(图(a)中的红色矩形区域)的HAADF-TEM照片;(c~e) 图(b)中对应的Co、Cr、Ni元素分布;(f) 降水SAED图(区域I(b)),(g) 图(b)中Ⅰ,Ⅱ,Ⅲ,Ⅳ区域Co,Cr,Ni元素含量[113]
Figure 65. Microstructural analysis of CoCrNi residual jet after penetration by TEM: (a) TEM images of CoCrNi residual jet, where the white dashed line marks the nanosized precipitations along grain boundaries; (b) HAADF-TEM image of the precipitation (red rectangle region in (a)); (c–e) Corresponding element distributions of Co, Cr, and Ni in (b); (f) SAED pattern ofprecipitation (region I in (b)); (g) Element content of Co, Cr, and Ni in region I, II, III, IV in (b)[113]
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