Spall in additively repaired 1100 aluminum: dynamic vs. quasistatic damage formation

Additive manufacturing is a promising method for making high value parts in aerospace and defense sectors, but questions remain around the reliability of such parts under

dynamic loading. This work experimentally investigates the behavior of additively repaired 1100 aluminum samples under both high strain-rate and quasistatic loading conditions. Samples were intentionally damaged and then repaired with wire-fed laser additive manufacturing. Quasistatic and dynamic testing was then carried out with in- situ diagnostics and post-mortem imaging to analyze the behavior and failure modes of the material. The results show that while the additive repair does not recover the strength or ductility of the original material under quasistatic loading, the performanceunder shock loading is more nuanced, with evidence of the repair quality shown to influence the spall, ejecta, and damage formation.