Metals manufactured by selective laser melting (SLM) with different directions exhibit different mechanical properties. This study conducted dynamic and static mechanical tests using a universal testing machine and split-Hopkinson bar (SHPB). The mechanical properties of 18Ni300 with 0° and 90° build directions manufactured by SLM were compared, and the micro-structure properties of the two build directions were analysed by metallographic tests. The Johnson–Cook (J-C) constitutive model was fitted according to the experimental results, and the obtained constitutive parameters were verified by numerical simulations. The results revealed that the constitutive model could predict the mechanical properties of 18Ni300 in a dynamic state. The build direction had little influence on the mechanical properties in a static state, but there was a significant difference in the dynamic state. The difference in the dynamic compressive yield strength of the 18Ni300 material manufactured by SLM with two build directions was 9.8%. The SLM process can be improved to produce 18Ni300 with uniform mechanical properties by studying the reasons for this difference.

Given the significantly large deformation and high strain exhibited by explosively formed projectiles (EFP) in penetration, their penetration performance into multi-layer targets differs from that of ordinary bullets or rigid projectiles. Therefore, it is necessary to investigate the ballistic performance and the damage mechanism of target deformation when an EFP penetrates a multi-layer target. This study conducted high-velocity impact tests of EFPs on four types of multi-layer steel targets, analyzing the damage morphology and deformation characteristics of multi-layer steel targets subjected to EFP penetration from both macro and micro levels. To investigate the anti-penetration performance of more target combinations at different EFP velocities, an accurate symmetrical finite element model of EFP penetration into multi-layer targets was established using Autodyn 16.0 finite element software and the SPH-FEM algorithm based on the symmetrical characteristics of the EFP and target structure. The experimental and simulation results showed that for a three-layer composite target, when the thickness of the middle layer remained constant, using the target layers with a front–rear target thickness ratio of less than one was beneficial for enhancing the anti-penetration performance of the targets against EFPs; when the EFP velocity was low and the residual velocity for penetrating a single-layer target was no more than 200 m/s, the anti-penetration performance of the two-layer target was optimal. When the EFP velocity exceeded 1500 m/s, the single-layer target exhibited the best anti-penetration performance to the EFP, and the more layers, the smaller the ballistic resistance. When the number of layers was more than six, the ballistic resistance of the multi-layer targets gradually tended to remain constant.

In urban combat, sub-millimeter inert metal powder is used to replace fragments in explosive bombs, which can effectively reduce collateral damage. In order to investigate the damage effect of high-speed metal particles on the human body, a particle ring filled with a charge was designed to create an explosion-driven particle cloud for the penetration ballistic gelatin. The particle ring was made of polytetrafluoroethylene (PTFE) and sub-millimeter tungsten powder. The dispersion properties of the particle cloud driven by the explosion were studied with high-speed photography and ballistic gelatin. Furthermore, the numerical simulation models of particle-penetrating gelatin based on the experimental results were established with the finite element method. The influences of the particle size and velocity on the penetration depth and cavity diameter was obtained. The relationship between the critical interference distance of the cavity and the distance between particles was determined. This paper provides references and theoretical support for the design of low collateral damage ammunition based on inert metal powder.

Heavy metal powders driven by explosions can enhance the near-field lethality of explosive warheads by forming a quasi-pressure field while reducing collateral damage at medium and long ranges. Incorporating polymers into high-content metal powders prevents powder sintering under explosive high pressure, enhancing dispersion uniformity and making them promising for controllable warhead applications. To describe the mechanical behavior of materials under impact loading, this paper investigates the dynamic and static mechanical properties and constitutive modeling of tungsten powder/polytetrafluoroethylene (PTFE) composites. Quasi-static compression tests and split Hopkinson pressure bar (SHPB) dynamic tests were conducted on composites with varying tungsten contents (0 wt%, 70 wt%, 80 wt%, and 90 wt%) and particle sizes (200 μm, 400 μm, and 600 μm), obtaining compressive stress–strain curves over a strain rate range of 0.001 to 3610 s⁻¹. The compressive strength of the composites slightly decreased with increasing tungsten particle size but increased with higher tungsten content. Under quasi-static compression, the compressive strength of the composites with 70 wt% and 80 wt% tungsten was lower than that of pure PTFE. This was due to the bonding strength between the tungsten particles and the resin being weaker than the cohesion within the resin. Additionally, the random distribution of the tungsten particles in the matrix led to shear cracks propagating along the phase interfaces, reducing the compressive strength. The compressive strength of the composites with 90 wt% tungsten exceeded that of pure PTFE, as the packed arrangement of the tungsten particles increased the material strength through particle extrusion and friction during compression. Under dynamic impact, the compressive strength of the composites was higher than that of pure PTFE, primarily due to particle extrusion and friction effects. The composites exhibited significant strain rate sensitivity, with both the compressive strength and critical strain increasing quasi-linearly with the strain rate. Based on the experimental data, a damage-modified Zhu–Wang–Tang (ZWT) viscoelastic model was employed to fit the data, effectively characterizing the uniaxial compressive constitutive behavior of tungsten powder/PTFE composites.

Tungsten powder/polytetrafluoroethylene (W/PTFE) composites have the potential to replace traditional metallic materials as casings for controllable power warheads. Under explosive loading, they generate high-density and relatively uniformly distributed metal powder particles, thereby enhancing close-range impact effects while reducing collateral damage. To characterize the material’s response under impact loading, plate impact tests were conducted to investigate the effects of tungsten content (70 wt%, 80 wt%, and 90 wt%) and tungsten particle size (200 μm, 400 μm, and 600 μm) on the impact behavior of the composites. The free surface velocity histories of the target plates were measured using a 37 mm single-stage light gas gun and a full-fiber laser interferometer (DISAR), enabling the determination of the shock velocity–particle velocity relationship to establish the equation of state. Experimental data show a linear relationship between shock velocity and particle velocity, with the 80 wt% and 90 wt% composites exhibiting similar shock velocities. The fitted slope increases from 2.792 to 2.957 as the tungsten mass fraction rises from 70 wt% to 90 wt%. With particle size increasing from 200 μm to 600 μm, the slope decreases from 3.204 to 2.756, while c₀ increases from 224.7 to 633.3. Comparison of the Hugoniot pressure curves of different specimens indicated that tungsten content significantly affects the impact behavior, whereas variations in tungsten particle size have a negligible influence on the Hugoniot pressure. A high tungsten content with small particle size (e.g., 90 wt% with ~200 μm) improves the overall compressive properties of composite materials. Based on the experimental results, a mesoscale finite element model consistent with the tests was developed. The overall error between the numerical simulations and experimental results was less than 5% under various conditions, thereby validating the accuracy of the model. Numerical simulations revealed the coupling mechanism between tungsten particle plastic deformation and matrix flow. The strong rarefaction unloading effect initiated at the composite’s free surface caused matrix spallation and jetting. Multiple wave systems were generated at the composite–copper interface, whose interference and coupling ultimately resulted in a nearly uniform macroscopic pressure field.

Equivalent-thickness conversion among metallic targets is important for vulnerability assessment and protection modelling, but conventional coefficients are often treated as material constants and seldom include fragment morphology. Penetration tests were conducted on 616 armor steel, Q235 steel, and LY12 aluminum alloy using steel spheres, tungsten spheres, and tungsten block fragments. A V50-based database was established, and failure mechanisms were examined from perforation morphology, exit-side SEM, and metallography. A semi-empirical ballistic-limit model was developed from key variables, with a residual correction term to describe the coupled deviation between fragment geometry and target response. The corrected model achieved a mean absolute percentage error of 7.91% and a coefficient of determination of 0.852. The conversion matrices show strong dependence on fragment type. For 616 steel converted to LY12 aluminum alloy, the coefficient increases from 2.50 for spherical fragments to 3.48 for tungsten blocks, giving a morphology-induced deviation of 39.03%. Thus, conversion should be defined by fragment type and target material rather than by a single material constant.