Spall

Last updated
Very high-speed photography of a small projectile striking a thin aluminium plate at 7,000 m/s. The impact causes the projectile to disintegrate, and generates a large number of small fragments from the aluminium (spallation). This can occur without penetration of the plate. Aluminium plate spalling.gif
Very high-speed photography of a small projectile striking a thin aluminium plate at 7,000 m/s. The impact causes the projectile to disintegrate, and generates a large number of small fragments from the aluminium (spallation). This can occur without penetration of the plate.

Spall are fragments of a material that are broken off a larger solid body. It can be produced by a variety of mechanisms, including as a result of projectile impact, corrosion, weathering, cavitation, or excessive rolling pressure (as in a ball bearing). Spalling and spallation both describe the process of surface failure in which spall is shed.

Contents

Spall from knapping obsidian arrowheads and other tools. These unique obsidians are found at Glass Buttes, Oregon. GVFKAStoneToolCraftsmanShowSpalls.jpg
Spall from knapping obsidian arrowheads and other tools. These unique obsidians are found at Glass Buttes, Oregon.

The terms spall, spalling, and spallation have been adopted by particle physicists; in neutron scattering instruments, neutrons are generated by bombarding a uranium (or other) target with a stream of atoms. The neutrons that are ejected from the target are known as "spall".

Mechanical spalling

Mechanical spalling occurs at high-stress contact points, for example, in a ball bearing. Spalling occurs in preference to brinelling, where the maximal shear stress occurs not at the surface, but just below, shearing the spall off.

One of the simplest forms of mechanical spalling is plate impact, in which two waves of compression are reflected on the free-surfaces of the plates and then interact to generate a region of high tensile stress inside one of the plates.

Spalling can also occur as an effect of cavitation, where fluids are subjected to localized low pressures that cause vapour bubbles to form, typically in pumps, water turbines, vessel propellers, and even piping under some conditions. When such bubbles collapse, a localized high pressure can cause spalling on adjacent surfaces.

Anti-tank warfare

A chunk of armour knocked from HMS New Zealand's 'X' turret during the Battle of Jutland on display at the Torpedo Bay Navy Museum in Auckland. Caption reads, "The chunk of armour plating you see here was gouged out of X turret by a German shell." Armour plating from HMS New Zealand.JPG
A chunk of armour knocked from HMS New Zealand 's 'X' turret during the Battle of Jutland on display at the Torpedo Bay Navy Museum in Auckland. Caption reads, "The chunk of armour plating you see here was gouged out of X turret by a German shell."

In anti-tank warfare, spalling through mechanical stress is an intended effect of high-explosive squash head (HESH) anti-tank shells and many other munitions, which may not be powerful enough to pierce the armour of a target. The relatively soft warhead, containing or made of plastic explosive, flattens against the armour plating on tanks and other armoured fighting vehicles (AFVs) and explodes, creating a shock wave that travels through the armour as a compression wave and is reflected at the free surface as a tensile wave breaking (tensile stress/strain fracture) the metal on the inside. The resulting spall is dangerous to crew and equipment, and may result in a partial or complete disablement of a vehicle and/or its crew. Many AFVs are equipped with spall liners inside their armour for protection.

A kinetic energy penetrator, if it can defeat the armour, generally causes spalling within the target as well, which helps to destroy or disable the vehicle and its crew. [1]

An early example of anti-tank weapon intentionally designed to cause spallation instead of penetration is the wz. 35 anti-tank rifle.

Spalling in mechanical weathering

Desquamation of dunite boulder Desquamation of dunite.JPG
Desquamation of dunite boulder

Spalling is a common mechanism of rock weathering, and occurs at the surface of a rock when there are large shear stresses under the surface. This form of mechanical weathering can be caused by freezing and thawing, unloading, thermal expansion and contraction, or salt deposition.

Unloading

Unloading is the release of pressure due to the removal of an overburden. When the pressure is reduced rapidly, the rapid expansion of the rock causes high surface stress and spalling.

Freeze–thaw weathering

Freeze–thaw weathering is caused by moisture freezing inside cracks in rock. Upon freezing its volume expands, causing large forces which cracks spall off the outer surface. As this cycle repeats the outer surface repeatedly undergoes spalling, resulting in weathering.

Some stone and masonry surfaces used as building surfaces will absorb moisture at their surface. If exposed to severe freezing conditions, the surface may flake off due to the expansion of the water. This effect can also be seen in terracotta surfaces (even if glazed) if there is an entrance for water at the edges.

Exfoliation

Granite dome exfoliation GeologicalExfoliationOfGraniteRock.jpg
Granite dome exfoliation

Exfoliation (or onion skin weathering) is the gradual removing of spall due to the cyclic increase and decrease in the temperature of the surface layers of the rock. Rocks do not conduct heat well, so when they are exposed to extreme heat, the outermost layer becomes much hotter than the rock underneath causing differential thermal expansion. This differential expansion causes sub-surface shear stress, in turn causing spalling. Extreme temperature change, such as forest fires, can also cause spalling of rock. This mechanism of weathering causes the outer surface of the rock to fall off in thin fragments, sheets or flakes, hence the name exfoliation or onion skin weathering.

Salt spalling

Salt spalling is a specific type of weathering which occurs in porous building materials, such as brick, natural stone, tiles and concrete. Dissolved salt is carried through the material in water and crystallizes inside the material near the surface as the water evaporates. As the salt crystals expand this builds up shear stresses which break away spall from the surface.

Some engineers[ weasel words ] believe that porous building materials can be protected against salt spalling by treatment with penetrating sealants which are hydrophobic (water repellent) and will penetrate deeply enough to keep water with dissolved salts well away from the surface.[ citation needed ] Great care and expert advice must be consulted, however, to ensure that any coating is compatible with the substrate in terms of breathability (ability to allow the release of vapours from inside while preventing water intrusion), or other serious problems can be created.

Chimneys show spalling damage before other portions of buildings because they are more exposed to the elements.

Corrosion

In corrosion, spalling occurs when a substance (metal or concrete) sheds tiny particles of corrosion products as the corrosion reaction progresses. Although they are not soluble or permeable, these corrosion products do not adhere to the parent material's surface to form a barrier to further corrosion, as happens in passivation. Spallation happens as the result of a large volume change during the reaction.

In the case of actinide metals (most notably the depleted uranium used in some types of ammunition), the material expands so strongly upon exposure to air that a fine layer of oxide is forcibly expelled from the surface. A slowly oxidised plug of metallic uranium can sometimes resemble an onion subjected to desquamation. The main hazard however arises from the pyrophoric character of actinide metals which can spontaneously ignite when their specific area is high. This property, along with the inherent toxicity and (for some to a lesser extent) radioactivity of these elements, make them dangerous to handle in metallic form under air. Therefore, they are often handled under an inert atmosphere (nitrogen or argon) inside an anaerobic glovebox.

Spalling in refractory concrete

There are two drivers for spalling of concrete: thermal strain caused by rapid heating and internal pressures due to the removal of water. Being able to predict the outcome of different heating rates on thermal stresses and internal pressure during water removal is particularly important to industry and other concrete structures.

Explosive spalling events of refractory concrete can result in serious problems. If an explosive spalling occurs, projectiles of reasonable mass (1–10 kg) can be thrust violently over many metres, which will have safety implications and render the refractory structure unfit for service. Repairs will then be required resulting in significant costs to industry. [2] [ failed verification ]

See also

Related Research Articles

<span class="mw-page-title-main">Concrete</span> Composite construction material

Concrete is a composite material composed of aggregate bonded together with a fluid cement that cures over time. Concrete is the second-most-used substance in the world after water, and is the most widely used building material. Its usage worldwide, ton for ton, is twice that of steel, wood, plastics, and aluminium combined.

<span class="mw-page-title-main">Rust</span> Type of iron oxide

Rust is an iron oxide, a usually reddish-brown oxide formed by the reaction of iron and oxygen in the catalytic presence of water or air moisture. Rust consists of hydrous iron(III) oxides (Fe2O3·nH2O) and iron(III) oxide-hydroxide (FeO(OH), Fe(OH)3), and is typically associated with the corrosion of refined iron.

<span class="mw-page-title-main">Reinforced concrete</span> Concrete with rebar

Reinforced concrete, also called ferroconcrete, is a composite material in which concrete's relatively low tensile strength and ductility are compensated for by the inclusion of reinforcement having higher tensile strength or ductility. The reinforcement is usually, though not necessarily, steel bars (rebar) and is usually embedded passively in the concrete before the concrete sets. However, post-tensioning is also employed as a technique to reinforce the concrete. In terms of volume used annually, it is one of the most common engineering materials. In corrosion engineering terms, when designed correctly, the alkalinity of the concrete protects the steel rebar from corrosion.

<span class="mw-page-title-main">Weathering</span> Deterioration of rocks and minerals through exposure to the elements

Weathering is the deterioration of rocks, soils and minerals through contact with water, atmospheric gases, sunlight, and biological organisms. Weathering occurs in situ, and so is distinct from erosion, which involves the transport of rocks and minerals by agents such as water, ice, snow, wind, waves and gravity.

<span class="mw-page-title-main">Corrosion</span> Gradual destruction of materials by chemical reaction with its environment

Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials by chemical or electrochemical reaction with their environment. Corrosion engineering is the field dedicated to controlling and preventing corrosion.

<span class="mw-page-title-main">Rebar</span> Steel reinforcement

Rebar, known when massed as reinforcing steel or reinforcement steel, is a steel bar used as a tension device in reinforced concrete and reinforced masonry structures to strengthen and aid the concrete under tension. Concrete is strong under compression, but has low tensile strength. Rebar significantly increases the tensile strength of the structure. Rebar's surface features a continuous series of ribs, lugs or indentations to promote a better bond with the concrete and reduce the risk of slippage.

<span class="mw-page-title-main">High-explosive squash head</span> Ammunition type

A high-explosive squash head (HESH), in British terminology, or a high-explosive plastic/plasticized (HEP), in American terminology, is a type of explosive projectile with plastic explosive that conforms to the surface of a target before detonating, which improves the transfer of explosive energy to the target. Squash head projectiles are similar to high-explosive projectiles and are well suited to many of the same targets. However, while HESH projectiles are not armour-piercing, they can defeat armored targets by causing spall, which can injure or kill a vehicle's occupants or detonate some types of ammunition.

<span class="mw-page-title-main">Spallation</span> Physical process

Spallation is a process in which fragments of material (spall) are ejected from a body due to impact or stress. In the context of impact mechanics it describes ejection of material from a target during impact by a projectile. In planetary physics, spallation describes meteoritic impacts on a planetary surface and the effects of stellar winds and cosmic rays on planetary atmospheres and surfaces. In the context of mining or geology, spallation can refer to pieces of rock breaking off a rock face due to the internal stresses in the rock; it commonly occurs on mine shaft walls. In the context of anthropology, spallation is a process used to make stone tools such as arrowheads by knapping. In nuclear physics, spallation is the process in which a heavy nucleus emits numerous nucleons as a result of being hit by a high-energy particle, thus greatly reducing its atomic weight. In industrial processes and bioprocessing the loss of tubing material due to the repeated flexing of the tubing within a peristaltic pump is termed spallation.

<span class="mw-page-title-main">Precast concrete</span> Construction material

Precast concrete is a construction product produced by casting concrete in a reusable mold or "form" which is then cured in a controlled environment, transported to the construction site and maneuvered into place; examples include precast beams, and wall panels for tilt up construction. In contrast, cast-in-place concrete is poured into site-specific forms and cured on site.

<span class="mw-page-title-main">Expansion joint</span> Construction assembly for absorbing thermally-induced volume changes

A expansion joint, or movement joint, is an assembly designed to hold parts together while safely absorbing temperature-induced expansion and contraction of building materials. They are commonly found between sections of buildings, bridges, sidewalks, railway tracks, piping systems, ships, and other structures.

<span class="mw-page-title-main">Fracture (geology)</span> Geologic discontinuity feature, often a joint or fault

A fracture is any separation in a geologic formation, such as a joint or a fault that divides the rock into two or more pieces. A fracture will sometimes form a deep fissure or crevice in the rock. Fractures are commonly caused by stress exceeding the rock strength, causing the rock to lose cohesion along its weakest plane. Fractures can provide permeability for fluid movement, such as water or hydrocarbons. Highly fractured rocks can make good aquifers or hydrocarbon reservoirs, since they may possess both significant permeability and fracture porosity.

<span class="mw-page-title-main">Thermal barrier coating</span> Form of exhaust heat management

Thermal barrier coatings (TBCs) are advanced materials systems usually applied to metallic surfaces on parts operating at elevated temperatures, such as gas turbine combustors and turbines, and in automotive exhaust heat management. These 100 μm to 2 mm thick coatings of thermally insulating materials serve to insulate components from large and prolonged heat loads and can sustain an appreciable temperature difference between the load-bearing alloys and the coating surface. In doing so, these coatings can allow for higher operating temperatures while limiting the thermal exposure of structural components, extending part life by reducing oxidation and thermal fatigue. In conjunction with active film cooling, TBCs permit working fluid temperatures higher than the melting point of the metal airfoil in some turbine applications. Due to increasing demand for more efficient engines running at higher temperatures with better durability/lifetime and thinner coatings to reduce parasitic mass for rotating/moving components, there is significant motivation to develop new and advanced TBCs. The material requirements of TBCs are similar to those of heat shields, although in the latter application emissivity tends to be of greater importance.

Landslide mitigation refers to several human-made activities on slopes with the goal of lessening the effect of landslides. Landslides can be triggered by many, sometimes concomitant causes. In addition to shallow erosion or reduction of shear strength caused by seasonal rainfall, landslides may be triggered by anthropic activities, such as adding excessive weight above the slope, digging at mid-slope or at the foot of the slope. Often, individual phenomena join to generate instability over time, which often does not allow a reconstruction of the evolution of a particular landslide. Therefore, landslide hazard mitigation measures are not generally classified according to the phenomenon that might cause a landslide. Instead, they are classified by the sort of slope stabilization method used:

After building of a new refractory-lined industrial furnace or equipment, or refractory maintenance or relining of existing equipment, a necessary step is the start-up of the operation, which usually involves heating-up the unit in a controllable way, in order to prevent spalling or shortening of the materials' predicted lifetime.

<span class="mw-page-title-main">Concrete degradation</span> Damage to concrete affecting its mechanical strength and its durability

Concrete degradation may have many different causes. Concrete is mostly damaged by the corrosion of reinforcement bars due to the carbonatation of hardened cement paste or chloride attack under wet conditions. Chemical damages are caused by the formation of expansive products produced by various chemical reactions, by aggressive chemical species present in groundwater and seawater, or by microorganisms. Other damaging processes can also involve calcium leaching by water infiltration and different physical phenomena initiating cracks formation and propagation. All these detrimental processes and damaging agents adversely affects the concrete mechanical strength and its durability.

Concrete has relatively high compressive strength, but significantly lower tensile strength. The compressive strength is typically controlled with the ratio of water to cement when forming the concrete, and tensile strength is increased by additives, typically steel, to create reinforced concrete. In other words we can say concrete is made up of sand, ballast, cement and water.

<span class="mw-page-title-main">Frost weathering</span> Mechanical weathering processes induced by the freezing of water into ice

Frost weathering is a collective term for several mechanical weathering processes induced by stresses created by the freezing of water into ice. The term serves as an umbrella term for a variety of processes, such as frost shattering, frost wedging, and cryofracturing. The process may act on a wide range of spatial and temporal scales, from minutes to years and from dislodging mineral grains to fracturing boulders. It is most pronounced in high-altitude and high-latitude areas and is especially associated with alpine, periglacial, subpolar maritime, and polar climates, but may occur anywhere at sub-freezing temperatures if water is present.

A pipe support or pipe hanger is a designed element that transfer the load from a pipe to the supporting structures. The load includes the weight of the pipe proper, the content that the pipe carries, all the pipe fittings attached to pipe, and the pipe covering such as insulation. The four main functions of a pipe support are to anchor, guide, absorb shock, and support a specified load. Pipe supports used in high or low temperature applications may contain insulation materials. The overall design configuration of a pipe support assembly is dependent on the loading and operating conditions.

Frost damage is caused by moisture freezing in the construction. Frost damage can occur as cracks, stone splinters and swelling of the material.

References

  1. "How M1 Tanks Work: Sabot". 7 May 2002.
  2. The Accelerated Drying of Refractory Concrete – Parts I and II, Volume 6, Issues 2 and 4 /The Refractory Worldforum