Numerical Modeling of the Experimental Dynamic Consolidation of Rapidly Solidified Metal Powders

A high explosive, dynamic consolidation process has recently been used to produce fully dense, crack-free monoliths from rapidly solidified stainless steel and aluminum powders. Numerical models of these experiments are developed to provide insight into the physical conditions within the powder material, the high explosive, and the supporting configuration. Numerical simulations from these models are used to design experiments and to explain post test observations. The two-dimensional CSQII simulation employs a distended material model for the powder, an elastic, perfectly-plastic model for the powder confinement devise, and a JWL state equation to characterize the high explosive reaction products. Behavior of the powder containing target configurations is simulated for two cases of interest: one stainless steel and one aluminum. In both, explosively loaded cover plates are initially in direct contact with the target/powder die piece. The resulting wave profile and propagation behavior is analyzed and graphically displayed for each case.