Novel experimental methods for investigating high speed friction of titanium-aluminum-vanadium/tool steel interface and dynamic failure of extrinsically toughened DRA composites

Dynamic deformation, flow, and failure are integral parts of all dynamic processes in materials. Invariably, dynamic failure also involves the relative sliding of one component of the material over the other. Advances in elucidation of these failure mechanisms under high loading rates has been of great interest to scientists working in this area. The need to develop new dynamic mechanical property tests for materials under well characterized and controllable loading conditions has always been a challenge to experimentalists. The current study focuses on the development of two experimental methods to study some aspects of dynamic material response.; The first part focuses on the development of a single stage gas gun facility for investigating high-speed metal to metal interfacial friction with applications to high speed machining. During the course of this investigation a gas gun was designed and built capable of accelerating projectiles upto velocities of 1 km/s. Using this gas gun pressure-shear plate impact friction experiments were conducted to simulate conditions similar to high speed machining at the tool-workpiece interface. The impacting plates were fabricated from materials representing the tribo-pair of interest. Accurate measurements of the interfacial tractions, i.e. the normal pressure and the frictional stress at the tribo-pair interface, and the interfacial slip velocity could be made by employing laser interferometry. Normal pressures of the order of 1-2 MPa were generated and slipping velocities of the order of 50 m/s were obtained. In order to illustrate the structure of the constitutive law governing friction, the study included experimental investigation of frictional response to step changes in normal pressure and interfacial shear stress. The results of these experiments indicate that sliding resistance for Ti6Al4V/CH steel interface is much lower than measured under quasi-static sliding conditions. Also the temperature at the interface strongly effects the sliding resistance of the interface. The experimental results deduced from the response of the sliding interface to step changes in normal pressure and the applied shear stress reinforce the importance of including frictional memory in the development of rate dependent state variable friction models.; The second part of the thesis presents an investigation into the dynamic deformation and failure of extrinsically toughened DRA composites. Experiments were conducted using the split Hopkinson pressure bar to investigate the deformation and flow behavior under dynamic compression loading. A modified Hopkinson bar apparatus was used to explore the dynamic fracture behavior of three different extrinsically toughened DRA composites. The study was paralleled by systematic exploration of the failure modes in each composite. For all the composites evaluated the dynamic crack propagation characteristics of the composites are observed to be strongly dependent on the volume fraction of the ductile phase reinforcement in the composite, the yield stress of the ductile phase reinforcement, the micro-structural arrangement of the ductile phase reinforcements with respect to the notch, and the impact velocity employed in the particular experiment.