To explain the axial fracture phenomenon of Explosively Formed Projectile (EFP), the fracture mechanism of long rod EFP during the forming phase is analyzed by the stress wave theory. When the velocity gradient [Formula: see text] between the head and tail parts exceeds the critical value [Formula: see text], the EFP would fracture in the axial direction. Based on the Johnson–Cook constitutive model parameters and the special conditions in the forming phase of EFP, the critical velocity gradient [Formula: see text] can be determined by theoretical calculation and then validated by experimental results for both copper and tantalum EFPs. The experimental results for EFP’s fracture agree well with the prediction of the theoretical analysis. The theoretical analysis method can be applied as an important measure to determine the critical velocity gradient and predict the fracture of long rod EFP, providing reference for the application of new kinds of high density materials in the EFP research area.

In order to study the dynamic response of tungsten heavy alloy materials under explosive loading, two kinds of typical tungsten alloys for explosively formed projectile (EFP) liner and one kind of existing EFP liner were tested in a flash X-ray experiment, with copper liner as a reference. Results showed that copper liner could form a coherent EFP, while 90W–9Ni–Co and W–25Re liners fractured to different extents. The microscopic features of the three kinds of metals were examined and compared with the original liner, and the microstructure evolutions under explosive loading were analyzed with the fracture model and mechanism of the two kinds of tungsten alloys’ fracture determined. Associated with the stress and strain conditions by numerical simulation, the fracture mechanism of tungsten heavy alloys can be analyzed. The crack-tip plastic zones of 90W–9Ni–Co and W–25Re are much smaller than copper, and due to the severe stress concentration at the tip of cracks, it is easy for cracks to propagate and trigger the cleavage in tungsten alloys. The value of a crack-tip plastic zone r(θ) can be used to explain the fracture phenomenon in explosive loading, which can be an alternative guideline for the material selection criteria of the EFP liner. The research results are significant in understanding the dynamic forming, microstructure evolution, and fracture mechanism of tungsten heavy alloys.

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