Correlating shaped charge performance with processing conditions and microstructure of an aluminum alloy 1100 liner enabled by a new method to arrest nascent jet formation

Aluminum-lined shaped charges are used in special applications where jet and / or slug residue in the target is undesired. The three different microstructures of the aluminum liners studied herein resulted from three different manufacturing interpretations of the same design. One interpretation was completely machining the liners from best available annealed round stock. The second was to cold-forge the liners from annealed round-stock in an open-die forge to near-final dimensions, and then machine the liners to the final dimensions. The third variant in this study was to use the above forged liner, but with annealing after the machining. These three manufacturing choices resulted in significant variations in shaped charge performance.;The goal of this research was to clarify the relationships between the liner metal microstructure and properties, and the corresponding shaped charge dynamic flow behavior. What began as an investigation into user-reported performance problems associated inherently with liner manufacturing processes and resultant microstructure, resolved into new understandings of the relationships between aluminum liner microstructure and shaped charge collapse kinetics. This understanding was achieved through an extensive literature review and the comprehensive characterization of the material properties of three variants of an 1100 aluminum shaped charge liner with a focus on collapse and nascent jet formation. The machined liner had a microstructure with large millimeter-sized grains and fine particles aligned in bands parallel to the charge axis. The forged liner microstructure consisted of very small one micrometer-sized (1 mum) subgrains and fine particles aligned largely in bands elongated parallel to the liner contour. The annealed liner was characterized by ten micrometer (10 mum) sized equiaxed grains with residual fine particles in the forged alignment.;This characterization was enabled by the development, execution and validation of a custom explosive experiment that delivered meaningful, full-scale shock deformed samples for analysis. The experiment arrested the collapse of actual, as-fabricated liners in the first microseconds of development. This experiment, performed with only 2% of the explosive mass of the full charge, revealed new insights into material-dependent variations in liner collapse including a striking image of the formation of a shaped charge jet axial hole.;The highly strain-hardened and elongated forged liner was the best performer of the three. Less energy from the explosive was dissipated by dislocation generation. This translated to more efficient flow whereas the softer materials behaved as shock absorbers delaying flow. A set of hypotheses was formulated and critiqued based on these observations. The key findings were the effects of grain size, and shear bands induced in the microstructure through cold work enabled efficient liner flow. These bands provide highly localized dislocation highways enabling the matrix adjacent to the bands to deform plastically at higher velocity. Where such bands are unavailable, the pressure must first develop bands of smaller grains, thus decreasing energy available for flow. Collapse velocities were then associated with the number of shear bands, the organization of mobile dislocations, material strain, and liner geometry.;Microstructures with the ability to deform with the direction of liner collapse at lower stresses will form jets with a higher velocity and elongate earlier. The effect is higher performance at shorter standoffs. This relationship can be used to predict material behavior under explosive load, guiding engineering choices while designing with respect to anticipated shock loading. The explosive experiment designed here has obvious application in refining the performance of other warheads, and in the hydrodynamic modeling of material properties.