Cracking and Dominant Stresses in the Throat Region of C-Shaped Solid Armatures

The throat region of solid armatures is subjected to significant stress and temperature during a railgun launch. Recovered aluminum alloy armatures show evidence of plastic deformation, melting, and even cracking in the throat region. Plastic deformation can result from magnetic pinch or thermal expansion forces and melting from ohmic heating. Although cracking is historically associated with grain boundary melting, the cracks observed in recently recovered armatures are likely a result of thermal stresses. Finite-element codes EMAP3D and DYNA3D were linked to assess stresses generated by magnetic forces, inertial loading, wear, and thermal expansions. For low-speed armatures, thermal stresses were found to be as important as magnetic stresses. The observed cracking is likely due to rapid cooling, similar to quench cracking, and may or may not occur during launch