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An experimental and numerical investigation of the


static and dynamic constitutive behaviour of aluminium
alloys
S Abotula and V B Chalivendra*
Department of Mechanical Engineering, University of Massachusetts, North Dartmouth, Massachusetts, USA

The manuscript was received on 7 April 2010 and was accepted after revision for publication on 11 June 2010.

DOI: 10.1243/03093247JSA655

Abstract: A split Hopkinson pressure bar (SHPB) set-up was used to investigate the dynamic
constitutive behaviour of commercial aluminium alloys both experimentally and numerically.
The study was conducted in a 500–10 000 s21 strain rate regime. Both regular solid and
modified hollow transmission bars were employed in realizing this strain rate regime. Four
different aluminium alloys, namely 7075-T4, 2024-T3, 6061-T6, and 5182-O, were considered
for investigation. A copper-110 alloy pulse shaper was used to obtain better force equilibrium
conditions at the bar–specimen interfaces. A plastic kinematic model was used to model the
rate-dependent behaviour of aluminium alloys using commercially available ANSYS LS-DYNA
software. Compared with the quasi-static condition, all four alloys showed a slight rate
dependency with an increased flow stress ranging from 50 to 100 MPa at much higher strain
rates. It was established from the final results that the experimentally determined dynamic
constitutive behaviour matches very well with the numerical value in a 2000–5000 s21 strain
rate regime.

Keywords: aluminium alloys, split hopkinson pressure, bar, strain rate, validation

1 INTRODUCTION constitutive behaviour of aluminium alloys 6061-


T651 and 7075-T6 in the 0.03–960 s21 strain rate
The growing requirement for fuel-efficient vehicles range, and found that the two aluminium alloys
has sparked renewed interest in aluminium alloys as a showed no strain rate sensitivity in that range. Holt et
replacement for other metals in aerospace and al. [3] used a Hopkinson pressure bar compression
automobile bodies owing to their high strength– set-up to study the strain rate dependence of the flow
weight ratio. When studying the crashworthiness of stress of aluminium alloys 1060-O, 1100-O, 6061-O,
these vehicles, the dynamic behaviour of aluminium 2024-O, 7075-O, 6061-T6, and 7075-T6 at strain rates
alloys must be well understood in developing numer- of 1023 s21 to 103 s21. In their experiments, the
ical models. Campbell [1] was the first to report on the authors reported that all aluminium alloys except
dynamic constitutive behaviour of aluminium alloys 6061-T6 and 7075-T6 showed a significant rate
by subjecting long rods to compression impact, dependency of flow stress. Nicholas [4] used a tensile
demonstrating the significant difference in flow stress Hopkinson pressure set-up to investigate the dy-
by comparison with that under quasi-static condi- namic constitutive behaviour of aluminium alloys
tions. Following these experiments, Maiden and 6061-T651 and 7075-T6, and it was reported that there
Green [2] conducted experiments using a Hopkinson was measurable strain rate sensitivity in tension at
pressure bar set-up to determine the dynamic high strain rates. Jenq and Sheu [5] reported on both
experimental and numerical analysis of the high-
*Corresponding author: Department of Mechanical Engineering, strain-rate compressive behaviour of aluminium alloy
University of Massachusetts Dartmouth, Group-II, 116, 285 Old 6061-O at strain rates of 361024 s21 to 36103 s21.
Westport Road, North Dartmouth, MA 02747, USA. They established that the dynamic yield strength of
email: vchalivendra@umassd.edu aluminium alloy 6061-O increases under high-strain-

JSA655 J. Strain Analysis Vol. 45


556 S Abotula and V B Chalivendra

rate loading conditions. Yadav et al. [6] also reported first three alloys (supplied by Speedy Metals, New
the increased flow stress of aluminium alloy 6061-T6 Berlin, Wisconsin) were in rod form with a diameter
under medium-strain-rate loading at 3500 s21. Re- of 12.5 mm, and AA 5182-O alloy (supplied by
cently, Smerd et al. [7] investigated the high-strain- Novelis Corporation, Mayfield Heights Ohio) was in
rate constitutive response and damage of two auto- sheet form with a thickness of 1.71 mm.
motive aluminium alloys AA5754 and AA5182 at both
room and elevated temperatures. They established
that the rate dependency of flow stress was low; 2.2 Quasi-static characterization
however, a marked increase in elongation was
The quasi-static compression tests were performed
measured with increase in strain rate. Also, Bragov
using the Instron materials testing system 5585. The
et al. [8] recently conducted both experimental and
specimens had a diameter of 12.7 mm and a length of
numerical studies to determine the rate dependency
25.4 mm as per the ASTM standard E9. Experiments
of two aluminium alloys AMg-6 and D-16 in a 0.003–
were performed at a strain rate of 0.006 s21, and the
7500 s21 strain rate regime. Their study indicated that
tests were continued until the crosshead extension
these two alloys show rate dependency, and their
reached a value of 2.5 mm. As crosshead displace-
numerical dynamic constitutive behaviour results,
ments are used to measure the compressive strains,
obtained using the Johnson–Cook model, matched
the machine compliance curve under compression,
well with corresponding experimental results.
as shown in Fig. 1, was plotted in order to calculate
Based on the reported literature, it was established
the actual specimen deformations. A higher-order
that there is no consistency in results concerning the
polynomial was fitted to develop the relationship
high-strain-rate constitutive behaviour of aluminium
between load and crosshead deformation. For a given
alloys. Moreover, no studies were reported to discuss
load, the crosshead deformation was subtracted from
the constitutive behaviour of commercially available
the total crosshead extension to determine the actual
aluminium alloys for a wide range of strain rates
axial deformation and the true strain of the specimen.
(0.006–10 000 s21). Hence, in this paper, a compre-
Load values provided by the testing machine were
hensive experimental and numerical investigation
used to determine the true stress of the specimen.
was performed on four different commercial alumi-
As AA 5182-O was received as a sheet material, a
nium alloys, 7075-T4, 2024-T3, 6061-T6, and 5182-O,
dog-bone specimen configuration as per ASTM
for the given range of strain rates. A copper-110 alloy
standard E8M was tested using the Instron materials
pulse shaper was used to obtain better force equili-
testing system 5582. Tests were performed using the
brium conditions at the bar–specimen interfaces. The
similar extension rate of 10 mm/min. In the case of
dynamic constitutive behaviour obtained from exper-
the tensile experiments, tests were conducted until
iments for a wide range of strain rates was compared
the specimen failed. It was assumed that crosshead
with that of numerical simulations performed using
commercial ANSYS LS-DYNA software.
The outline of this paper is as follows. In section 2,
the materials and experimental details, such as quasi-
static characterization and dynamic characterization,
are discussed. In section 3, numerical design con-
siderations are addressed. In section 4, the results of
experiments and numerical simulations are given, and
a comparison of numerical results with experimental
results is presented. Section 5 sets out the conclusions
of this study.

2 EXPERIMENTAL

2.1 Materials
Four different aluminium alloys, namely 6061-T6,
2024-T3, 7075-T4, and AA 5182-O, were considered Fig. 1 Machine compliance curve obtained for the
in this study. All four alloys have been used either in Instron materials testing system under quasi-
the aerospace or in the automobile industry. The static compression

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Static and dynamic constitutive behaviour of aluminium alloys 557

compliance under tension is very small, and hence Using one-dimensional (1D) wave theory [9], the true
the true strain of the specimen was determined from strain, es , and true stress, ss , in the specimen can be
the crosshead displacements. determined from the reflected and transmitted strain
pulses respectively, as given by the equations
ðt
2.3 Dynamic characterization {2cb
es ~ er ðt Þ dt ð1Þ
Ls 0
The traditional split Hopkinson pressure bar (SHPB)
was used to study the dynamic constitutive behaviour
Ab
of aluminium alloys 6061-T6, 2024-T3, and 7075-T4. ss ~Eb et ðt Þ ð2Þ
As
SHPB consists of a striker bar, a solid incident bar, and a
solid transmission bar, as shown in Fig. 2, and they are
where er ðt Þ is the reflected strain pulse, et ðt Þ is the
all made of maraging steel [9]. A striker bar with a pffiffiffiffiffiffiffiffiffiffiffiffiffi
transmitted strain pulse, cb ~ Eb =rb is the long-
diameter of 12.7 mm and two different lengths (100 mm
itudinal wave speed, Eb is Young’s modulus of the bar
for generating low strain rates, 50 mm for generating
material, rb is the density of the bar material, Ls is the
high strain rates) was used. Both the incident bar and
thickness of the specimen, Ab is the cross-sectional
the transmission bar had a diameter of 12.5 mm and a area of the bar, and As is the cross-sectional area of
length of 1220 mm. The specimen, with a diameter of the specimen.
6.35 mm and a thickness of 3 mm, was sandwiched As alloy AA 5182-O had a thickness of 1.70 mm, a
between the incident bar and the transmission bar. diameter of 3.22 mm was used in order to eliminate
Molybdenum disulfide lubricant was applied between errors due to longitudinal and radial inertia [10]. It
the specimen and the contacting end bar surfaces to was established in the present study that the
minimize the friction. transmission pulse generated in an experiment using
When the striker impacts against the incident bar, a specimen of such small dimensions is not large
an elastic compressive stress pulse, referred to as the enough for data on the true strain and true stress
incident pulse, is generated, and the generated pulse values to be analysed. Hence, a modified Hopkinson
deforms the pulse shaper at the impact end and pressure bar set-up using an aluminium 7075-T651
creates a ramp in the incident pulse which further solid incident bar and a hollow transmission bar was
propagates along the incident bar. When the incident used. An aluminium end-cap was press fitted into
pulse reaches the specimen, part of it reflects back the hollow tube to support the specimen at the
into the incident bar (reflected pulse) in the form of a specimen transmission bar interface [11]. For this
tensile pulse owing to the impedance mismatch at the alloy, an aluminium striker bar with a diameter of
bar–specimen interface, and the remaining part is 12.7 mm and, again, two different lengths (305 mm
transmitted (transmission pulse) to the transmission for generating low strain rates, 100 mm for generat-
bar. Axial strain gauges mounted on the surfaces of ing high strain rates) was used. The expression for
the incident bar and the transmission bar provide the true stress, ss , is the same as equation (2). How-
time-resolved measurements of the elastic strain ever, the equation for the true strain, es , in the speci-
pulses in the bars. Different strain rates are obtained men for the modified Hopkinson pressure set-up will
by varying the velocity at which the striker impacts. also involve the incident strain pulse, ei ðt Þ, in addi-
tion to the reflected strain pulse, er ðt Þ, as given by the
equation [11]
ðt
{4cb
es ~ ½0:32ei ðt Þz0:82er ðt Þ dt ð3Þ
Ls 0

3 NUMERICAL DESIGN CONSIDERATIONS

To study the dynamic behaviour of these aluminium


alloys, a three-dimensional (3D) split Hopkinson
pressure bar set-up was modelled using the com-
Fig. 2 Schematic of the split Hopkinson pressure bar mercially available ANSYS LS-DYNA finite element
set-up software package. The model consisted of three

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558 S Abotula and V B Chalivendra

parts: the incident bar, the specimen, and the where sy is the dynamic yield stress, which varies
transmission bar, and the dimensions of all three with strain rate, s0 is the quasi-static yield stress, e_ is
parts were similar to those in the experiments. All the strain rate, C and P are the Cowper–Symonds
three components were modelled using 3D Solid 164 strain rate parameters, eeff p is the effective plastic
elements. Mapped meshing was used for the entire strain, and Ep is the plastic hardening modulus,
model to obtain accurate results, with ten elements which is given by the equation
across the radius of the bars and a total of 280
elements along the length of the bars, as shown E
in Fig. 3. The mesh was refined at the middle of Ep ~Etan ð5Þ
E{Etan
the bars to record strain pulses with a smaller
averaging error. Symmetric boundary conditions Except for C and P, all other parameters were
Uy ~0 were assigned to the bottom flat surface, obtained from experimental data. Quasi-static true
and Ux ~0 to the vertical flat surface of each quarter- stress–strain experimental data obtained for each
bar, as shown in Fig. 3. For bar–specimen interfaces, aluminium alloy were used to calculate the yield
surface to surface with tied contact was used with a stress, s0 , the tangent modulus, and the effective
typical coefficient of friction value of 0.14. Loading plastic strain. The 0.2 per cent offset method was
pulses as received from the strain gauges located used to determine the yield stress for both static and
on the incident bar of each experiment for the given dynamic experiments. The tangent modulus was
strain rate were used in the numerical simulations determined by taking the slope of the plastic
as input and applied on the left end of the incident deformation part of the stress–strain curve. Isotropic
bar. All four aluminium alloys were modelled in hardening was considered in the model, and hence b
ANSYS LS-DYNA for strain rates ranging from 1700 took a value of 1 [11]. Parameters C and P were
to 7000 s21. determined by fitting experimental data to the
The Cowper–Symonds model based on a plastic Cowper–Symonds model as a function of the strain
kinematic material model [12] available in ANSYS rate for all four aluminium alloys. The material
LS-DYNA was used to model the strain rate con- properties and the constants of the model for
stitutive material behaviour of all four aluminium different aluminium alloys are listed in Table 1.
alloys. This model scales the yield stress by the
strain-rate-dependent factor, as given by the equa-
tion 4 RESULTS
" 1=P #
e_  4.1 Experimental results
sy ~ 1z s0 zbEp eeff
p ð4Þ
C 4.1.1 Quasi-static response
The true stress–strain curves for all four aluminium
alloys under quasi-static conditions are shown in
Fig. 4. All these curves have two regions: an initial
linear portion and a non-linear portion. The slope of
the initial linear portion for all aluminium alloys

Table 1 Parameters of the plastic kinematic model for


the different aluminium alloys
Alloy type
Parameters 6061-T6 2024-T3 7075-T4 AA 5182-O
3
Density (kg/m ) 2850 2850 2850 2850
E (GPa) 72 72 72 72
Poisson’s ratio 0.33 0.33 0.33 0.33
Yield stress (MPa) 252 400 576 130
Tangent modulus 600 600 650 400
(MPa)
B 1 1 1 1
C 25 000 30 000 65 000 10 000
Fig. 3 Modelling of the SHPB set-up using ANSYS LS- P 0.95 1.2 0.95 0.75
Failure strain 0.4 0.4 0.35 0.7
DYNA

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Static and dynamic constitutive behaviour of aluminium alloys 559

provides enough time for the specimen to experience


maximum load and generates good equilibrium condi-
tions. It should be noted here that good equilibrium
conditions were realized for all aluminium alloys up to a
maximum strain rate value of 4000 s21, and reasonably
decent force equilibrium conditions were achieved
beyond a strain rate of 5500 s21.
Typical force equilibrium conditions of alloy 6061-
T6 for strain rates between 719 and 3215 s21 are
shown in Fig. 6. The solid line represents the ideal
force ratio of 1.0. The dynamic true stress–strain
curves for different strain rates are plotted along
with quasi-static true stress–strain curves for each
aluminium alloy in Figs 7 to 10. As shown in Fig. 7,
alloy 7075-T4 shows no significant rate sensitivity,
Fig. 4 True compressive stress–strain curve under
quasi-static loading conditions

remains the same. Alloy 7075-T4 has the highest


yield strength, and AA 5082-O has the lowest yield
strength compared with the other alloys. The flow
stress of all aluminium alloys increases at a slower
rate as the true strain increases.

4.1.2 Dynamic constitutive response


Experiments were carried out at different strain rates
ranging from 500 to 10 000 s21. The typical real-time
strain pulses obtained for alloy 6061-T6 at an average
strain rate of 3025 s21 are shown in Fig. 5. It can be seen
from the figure that the pulse shaper generated a Fig. 6 Typical force equilibrium condition of all four
aluminium alloys at a strain rate of 2500 s21
significant ramp in the incident pulse. This initial ramp

Fig. 5 Typical strain pulses recorded from strain Fig. 7 True compressive stress–strain curve for alloy
gauges mounted on bars 7075-T4

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560 S Abotula and V B Chalivendra

Fig. 8 True compressive stress–strain curve for alloy Fig. 10 True compressive stress–strain curve for alloy
2024-T3 AA 5182-O

and there is no change in the yield strength as the conditions. The difference in yield strength (deter-
strain rate increases. However, the difference in flow mined using the 0.2 per cent offset method) between
stress at higher strain rates compared with quasi- quasi-static and dynamic conditions ranges between
static conditions (0.006 s21) for strain values of 6–8 35 and 70 MPa. The flow stress at higher strain rates
per cent is around 100 MPa. Also, alloy 2024-T3 is around 100 MPa greater than that under quasi-
shows rate insensitivity for all dynamic strain rates, static conditions. Similarly to other alloys, AA 5182-
as shown in Fig. 8. There is a considerable difference O, as shown in Fig. 10, also provides a slight increase
in their yield stress under quasi-static and dynamic in flow stress at higher strain rates compared with
conditions, ranging between 80 and 140 MPa. The quasi-static conditions. However, there is no sig-
flow stress at dynamic strain rates is around 50– nificant change in flow stress between lower and
70 MPa higher than that under quasi-static condi- medium strain rates. The difference in yield stress
tions. between quasi-static and dynamic constitutive be-
For alloy 6061-T6, as shown in Fig. 9, there is a haviour at higher strain rates is approximately 70–
significant difference in yield stress and flow stress at 100 MPa.
dynamic strain rates compared with quasi-static

Fig. 11 Comparison of incident, reflected and trans-


Fig. 9 True compressive stress–strain curve for alloy mitted pulses for experimental and numerical
6061-T6 analysis

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Static and dynamic constitutive behaviour of aluminium alloys 561

4.2 Numerical simulations for strain rates ranging from 1700 to 7500 s21. It was
Before dynamic characterization of the aluminium established that the true stress–strain behaviour
alloy simulations, the SHPB numerical model is first predicted by the Cowper–Symonds model for strain
validated by comparing typical strain pulses ob- rates beyond 7500 s21 was significantly different
tained from simulation with those in experiments. A from that in experiments. Hence, comparison of
comparison of incident, reflected pulses and trans- numerical results with experimental results for strain
mitted strain pulses for alloy 6061-T6 at an average rates beyond 7500 s21 is not discussed in this paper.
strain rate of 3500 s21 is shown in Fig. 11. There is a A comparison of the numerical dynamic constitutive
very good match between experimental and numer- behaviour of the four different aluminium alloys
ical strain pulses. This matching ensures that the with that in experiments for four different strain
quarter-bar with symmetric boundary conditions rates is shown in Figs 12 to 15.
does not disperse and attenuate the strain pulses as As shown in Fig. 12, the Cowper–Symonds model
they travel along the bar. Similar matching was predicted the dynamic constitutive behaviour of
identified for all other aluminium alloys considered alloy 7075-T4 very well for a medium strain rate
in this study. Similarly to experiments, time-resolved (3225 s21) and showed slight deviation from experi-
strain pulses were recorded at the middle of the bars ments at both lower strain rates and higher strain
in numerical simulations. These pulses were later rates. The yield stress values of numerical simula-
analysed to obtain the true stress–strain behaviour tions matched well with those of experiments for all

Fig. 12 Comparison of numerical dynamic true stress–strain behaviour with that of experiments
for alloy 7075-T4: (a) strain rate 1777 s21; (b) strain rate 2412 s21; (c) strain rate 4019 s21;
(d) strain rate 7057 s21

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562 S Abotula and V B Chalivendra

Fig. 13 Comparison of the numerical dynamic true stress–strain behaviour with that of
experiments for alloy 2024-T3: (a) strain rate 2169 s21; (b) strain rate 3235 s21; (c) strain
rate 5076 s21; (d) strain rate 7202 s21

strain rates. However, the flow stress values differ at well, but the flow stress deviates from experiments
both low and high strain rates. For alloy 2024-T3, as at around 4 per cent true strain, and the difference
shown in Fig. 13, the model showed a slight reaches a maximum of 200 MPa. In general, the
variation in both yield stress and flow stress for all deviations found in yield strength and flow stress
strain rates. Moreover, for all strain rates, a flow for all four aluminium alloys at different strain
stress difference of 50–100 MPa can be seen. rates, as illustrated in Figs 12 to 15, might be
For alloy 6061-T6, as shown in Fig. 14, the model attributed to errors in measuring the dynamic yield
predicted very well for all strain rates except strength (determined using the 0.2 per cent of-
7505 s21. For a strain rate of 7505 s21, the flow stress fset method) and improper fitting of experimental
deviates significantly, and the difference ranges from data in generating the Cowper–Symonds model
50 to 200 MPa for a true strain range of 2–16 per parameters.
cent. From Fig. 15 it can be seen that the model
predicted the dynamic constitutive behaviour of AA
5182-O very well except at high strain rates. For a 5 CONCLUSIONS
strain rate of 5114 s21, the yield stress value matches
well, and the flow stress also matches well until Comprehensive experiments and numerical simula-
a true strain value of 10 per cent. For a strain rate tions were conducted to understand the dynamic
value of 7266 s21, the yield stress matches very constitutive behaviour of four commercial alumi-

J. Strain Analysis Vol. 45 JSA655


Static and dynamic constitutive behaviour of aluminium alloys 563

Fig. 14 Comparison of numerical dynamic true stress–strain behaviour with that of experiments
for alloy 6061-T6: (a) strain rate 2206 s21; (b) strain rate 3025 s21; (c) strain rate 5237 s21;
(d) strain rate 7505 s21

nium alloys for a wide range of strain rates between the flow stress at dynamic strain rates is also
0.006 and 10 000 s21 using a split Hopkinson pres- around 50–70 MPa higher than under quasi-static
sure bar set-up. The following are the major out- conditions.
comes of this study: 3. For alloy 6061-T6 there is a significant difference in
both yield strength and flow stress at dynamic
1. Alloy 7075-T4 showed no significant rate sensi- strain rates compared with quasi-static conditions.
tivity at higher strain rates, and the yield strength The difference in yield strength between quasi-
values under dynamic conditions are similar to static and dynamic conditions ranges from 35 to
those under quasi-static conditions. However, the 70 MPa. The flow stress at higher strain rates is
difference in flow stress at high strain rates around 100 MPa greater than under quasi-static
compared with quasi-static conditions (0.006 s21) conditions.
for true strain values of 6–8 per cent is around 4. AA 5182-O shows a slight increase in flow stress at
100 MPa. higher strain rates compared with quasi-static
2. Alloy 2024-T3 also shows rate insensitivity for all conditions. However, there is no significant
dynamic strain rates. However, there is a con- change in flow stress between lower and medium
siderable difference in dynamic yield strength at strain rates. The difference in yield stress between
high strain rates compared with quasi-static quasi-static and dynamic constitutive behaviour
conditions, and the difference ranges from 80 to at higher strain rates is approximately 70–
140 MPa. In addition to yield strength difference, 100 MPa.

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564 S Abotula and V B Chalivendra

Fig. 15 Comparison of numerical dynamic true stress–strain behaviour with that of experiments
for alloy AA 5182-O: (a) strain rate 1018 s21; (b) strain rate 3533 s21; (c) strain rate
5114 s21; (d) strain rate 7266 s21

5. For all the aluminium alloys, the predicted from 1023 to 104 in/in/s. J. Appl. Mechanics, 1966,
dynamic true stress–strain response using the 33, 496–504.
Cowper–Symonds material model matched well 3 Holt, D. L., Babcock, S. G., Green, S. J., and Maiden,
C. J. The strain-rate dependence of the flow stress in
with that in experiments at medium strain rates
some aluminum alloys. J. Appl. Mechanics, 1967, 60,
(2000–5000 s21). However, the model provided a 152–159.
significant difference in flow stress at high strain 4 Nicholas, T. Tensile testing of materials at high
rates and predicted poorly at very high strain rates rates of strain. Expl Mechanics, 1981, 21, 177–185.
(beyond 7500 s21). 5 Jeng, S. T. and Sheu, S. L. An experimental and
numerical analysis of high strain-rate compression
F Authors 2010 behavior of 6061-O aluminum alloys. Comput.
Struct., 1994, 52, 27–34.
6 Yadav, S., Chichili, D., and Ramesh, K. T. The
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