Numerical analysis of hypervelocity impact-induced debris formation in Weldox 700E high-strength structural steel

The study of debris formation is one of the greatest aspects of hypervelocity impact. Steel has a high melting point temperature and leak proof at cryogenic temperature which increases the possibility to use as a shielding material in spacecraft. The present study focuses on Weldox 700 E structural steel, a high strength material used in aerospace and defense industries for the shielding purpose. The present study analyses the mechanism of debris formation in variable thickness (4–8 mm) of target plates during hypervelocity impact using cylindrical and spherical projectile through numerical method. The study indicates that projectile geometry and target thickness significantly influence pressure-wave propagation, plastic deformation, temperature rise, failure mechanisms, and debris morphology. Increasing the plate thickness from 4 to 8 mm confines pressure propagation, reduces debris dispersion, and produces a shorter and narrower debris cloud. The effect of spall formation is more pronounced for cylindrical projectiles than for spherical projectiles as the target plate thickness increases. Cylindrical projectiles produce an axial, column-shaped debris cloud, whereas spherical projectiles generate a diffuse, mushroom-shaped debris cloud due to shock-induced radial debris ejection. Maximum debris dispersion occurs for spherical projectiles impacting thinner plates, while thicker plates with cylindrical projectiles produce more focused debris. Further, the increasing plate thickness reduces the length of debris spread and reduces the debris width, resulting in steeper and more confined cone for debris cloud. The findings improve the understanding of hypervelocity impact physics and provide guidance for the design of advanced protective structures and spacecraft shielding systems.