Phase field fracture in elastoplastic solids: a stress-state, strain-rate, and orientation dependent model in explicit dynamics and its applications to additively manufactured metals

• An explicit phase field model is developed for dynamic ductile fracture. • Rate, stress state, and orientation dependencies are considered. • Phase field model is calibrated by material samples. • Phase field model is validated by crack propagation samples. • Orientation should be considered to predict dynamic crack paths. Phase field models have gained growing popularity in analysing fracture behaviour of materials. However, few have been explored to simulate dynamic ductile fracture to date. This study aims to develop a phase field framework considering strain rate, stress state, and orientation dependent ductile fracture under dynamic loading. Firstly, governing equations of displacement and phase fields are formulated in an explicit finite element framework. Secondly, constitutive relations are established with a hypoelastic-plasticity framework, encompassing the influence of material orientation and strain rate on both plasticity and fracture initiation. Stress states dependent fracture initiation is also considered. Thirdly, finite element implementation and corotational formulation for constitutive equations are derived. To validate the proposed model, finally, additively manufactured samples, involving material-level and crack propagation specimens are tested under dynamic loading conditions. Overall, the proposed phase field model can properly reproduce the experimental force-displacement curves and crack paths. Uniaxial tension tests reveal that a higher strain rate can lead to a higher hardening curve and lower ductility. Other material specimens further demonstrate the capability to predict stress state and orientation dependent dynamic fracture. To simulate dynamic crack paths accurately, it is necessary to consider anisotropic fracture initiation. Lastly, the phase field model was applied for the first time to predict the dynamic response of triply periodic minimal surface (TPMS) structures. Dynamic crack patterns were effectively captured, and the fracture mechanisms were thoroughly analysed. This study provides an explicit phase field framework for dynamic ductile fracture, with applications to additively manufactured materials and structures.