Patent Application
20190072365
This application relates to compositionally-graded metal-ceramic structures and, more particularly, to high-energy impact protection by way of compositionally-graded metal-ceramic structures.
High-energy impact protection is often desired for a variety of applications. As one example, space vehicles encounter various space debris, such as micrometeoroids and man-made orbital debris. Therefore, space vehicles typically include a high-energy impact protection layer to mitigate the risks associated with collisions with space debris. As another example, certain types of terrestrial vehicles, such as aircraft (e.g., helicopters) and ground vehicles (e.g., military and law enforcement vehicles), are armored to protect against ballistic threats.
In the case of ballistic threats, current state-of-the-art armor is typically constructed from ceramic materials, such as alumina, silicon carbide and boron carbide, which tend to blunt, erode, decelerate and deflect projectiles. Alumina is relatively low-cost, but requires a higher area density to achieve effective protection, thereby limiting the use of alumina-based armor to terrestrial vehicles. When weight is an important consideration, such as for aircraft, more expensive boron carbide-based armor is commonly used.
Unfortunately, the ceramic materials used to manufacture current state-of-the-art armor are relatively heavy, thereby increasing vehicle fuel consumption and limiting useful applications. Such ceramic materials also present manufacturability issues that increase overall cost and limit fabrication options. Furthermore, the ceramic materials of current state-of-the-art armor tend to shatter upon impact, leaving little or no material to impede subsequent impacts. As such, current state-of-the-art armor is relatively dense/heavy, yet offers only limited multi-hit protection.
Accordingly, those skilled in the art continue with research and development efforts in the field of high-energy impact protection.
In one example, the disclosed compositionally-graded structure includes a body having a first major surface and a second major surface opposed from the first major surface along a thickness axis, the body including a metallic component and a ceramic component, wherein a concentration of the ceramic component in the body is a function of location within the body along the thickness axis, wherein transitions of the concentration of the ceramic component in the body are continuous such that distinct interfaces are not macroscopically established within the body, and wherein the concentration of the ceramic component is at least 95 percent by volume at at least one location within the body along the thickness axis.
In one example, the disclosed armor panel includes a compositionally-graded structure and an anti-spalling layer. The compositionally-graded structure includes a body having a first major surface and a second major surface opposed from the first major surface along a thickness axis, the body including a metallic component and a ceramic component, wherein a concentration of the ceramic component in the body is a function of location within the body along the thickness axis, wherein transitions of the concentration of the ceramic component in the body are continuous such that distinct interfaces are not macroscopically established within the body, and wherein the concentration of the ceramic component is at least 95 percent by volume at at least one location within the body along the thickness axis. The anti-spalling layer is adjacent to the second major surface of the body.
In one example, the disclosed method for manufacturing a compositionally-graded structure includes steps of: (1) assembling a powder layup that includes at least a first powdered material and a second powdered material, the first powdered material including a ceramic component and the second powdered material including a metallic component, the powder layup including: (a) a first layer having a first concentration of the ceramic component; (b) a second layer having a second concentration of the ceramic component and a first concentration of the metallic component; and (c) a third layer having a third concentration of the ceramic component and a second concentration of the metallic component; (2) pressing the powder layup to yield a compact; and (3) heat treating the compact.
Other examples of the disclosed compositionally-graded metal-ceramic structures, armor panels, and methods will become apparent from the following detailed description, the accompanying drawings and the appended claims.
Referring to
The body 12 of the compositionally-graded structure 10 may be a consolidated mass, and may include a metallic component 18 and a ceramic component 20. Plural metallic components 18 and/or plural ceramic components 20 may be used without departing from the scope of the present disclosure. Furthermore, other components (other than the metallic component 18 and the ceramic component 20) may be included in the body 12, whether by addition or in situ formation, without departing from the scope of the present disclosure.
The metallic component 18 of the body 12 of the compositionally-graded structure 10 may be a metal or metal alloy. As one specific, non-limiting example, the metallic component 18 of the body 12 may be a titanium alloy, such as Ti-6Al-4V. As another specific, non-limiting example, the metallic component 18 of the body 12 may be an aluminum alloy, such as a 7000-series aluminum alloy (e.g., aluminum 7075). As yet another specific, non-limiting example, the metallic component 18 of the body 12 may be a nickel alloy, such as a nickel-based superalloy (e.g., Inconel 625).
The ceramic component 20 of the body 12 of the compositionally-graded structure 10 may be a ceramic material. Various ceramic materials may be used as the ceramic component 20 of the body 12. Examples of ceramic materials suitable for use as the ceramic component 20 of the body 12 include, without limitation, titanium diboride (TiB2), titanium boride (TiB), titanium carbide (TiC), chromium carbide (e.g., Cr23C6), silicon carbide (SiC), tungsten carbide (WC), and the like.
The composition of the ceramic component 20 may be selected based on the composition of the metallic component 18, and vise versa. In a particular implementation, a metal element may be common to both the metallic component 18 and the ceramic component 20. In one expression, titanium may be common to both the metallic component 18 and the ceramic component 20. In another expression, aluminum may be common to both the metallic component 18 and the ceramic component 20. In yet another expression, chromium may be common to both the metallic component 18 and the ceramic component 20.
Thus, the body 12 of the compositionally-graded structure 10 may be formed from a material system that includes both a metallic component 18 and a ceramic component 20. While the compositions of the metallic component 18 and the ceramic component 20 are design choices that may widely vary without departing from the scope of the present disclosure, it is believed that certain advantages may be gained by selecting a material system in which there is a metal element common to both the metallic component 18 and the ceramic component 20. Specific, non-limiting examples of such material systems include titanium alloy/titanium diboride; titanium alloy/titanium boride/titanium diboride; titanium alloy/titanium boride; titanium alloy/titanium carbide; aluminum alloy/aluminum oxide; nickel-chromium alloy/chromium carbide.
As shown in
Referring to
As one specific, non-limiting example, the concentration of the metallic component 18 may linearly transition from zero (or about zero) proximate the first major surface 14 to about 100 percent by volume proximate the second major surface 16, while the concentration of the ceramic component 20 may linearly transition from about 100 percent by volume proximate the first major surface 14 to zero (or about zero) proximate the second major surface 16.
As another specific, non-limiting example, the concentration of the metallic component 18 may linearly transition from at most about 5 percent by volume proximate the first major surface 14 to at least about 90 percent by volume proximate the second major surface 16, while the concentration of the ceramic component 20 may linearly transition from at least about 95 percent by volume proximate the first major surface 14 to at most about 10 percent by volume proximate the second major surface 16.
As yet another specific, non-limiting example, the concentration of the metallic component 18 may linearly transition from at most about 5 percent by volume proximate the first major surface 14 to at least about 80 percent by volume proximate the second major surface 16, while the concentration of the ceramic component 20 may linearly transition from at least about 95 percent by volume proximate the first major surface 14 to at most about 20 percent by volume proximate the second major surface 16.
Alternatively, the concentrations of the metallic component 18 and/or the ceramic component 20 versus location within the body 12 along the thickness axis T may be non-linear functions. In one variation, the concentration of the metallic component 18 may transition from a relatively low concentration proximate the first major surface 14 to a relatively high concentration proximate the second major surface 16, while the concentration of the ceramic component 20 may transition from a relatively high concentration proximate the first major surface 14 to a relatively low concentration proximate the second major surface 16. In another variation, the concentration of the metallic component 18 may transition from a relatively low concentration proximate the first major surface 14 to a relatively high concentration between the first and second major surfaces 14, 16, and then back to a relatively low concentration proximate the second major surface 16. In yet another variation, the concentration of the ceramic component 20 may transition from a relatively low concentration proximate the first major surface 14 to a relatively high concentration between the first and second major surfaces 14, 16, and then back to a relatively low concentration proximate the second major surface 16. Therefore, the composition of the body 12 may be continuously transitioned in numerous ways along the thickness axis T.
Referring to
Referring to
The disclosed compositionally-graded structure 10 may have a relatively high concentration of the ceramic component 20 at at least one location within the body 12 along the thickness axis T. The location having a relatively high concentration of the ceramic component 20 may be proximate the first major surface 14 of the body 12, though various other configurations are also contemplated and will not result in a departure from the scope of the present disclosure. As one example, the concentration of the ceramic component 20 may be at least about 95 percent by volume at at least one location within the body 12 along the thickness axis T. As another example, the concentration of the ceramic component 20 may be at least about 96 percent by volume at at least one location within the body 12 along the thickness axis T. As another example, the concentration of the ceramic component 20 may be at least about 97 percent by volume at at least one location within the body 12 along the thickness axis T. As another example, the concentration of the ceramic component 20 may be at least about 98 percent by volume at at least one location within the body 12 along the thickness axis T. As another example, the concentration of the ceramic component 20 may be at least about 99 percent by volume at at least one location within the body 12 along the thickness axis T. As yet another example, the concentration of the ceramic component 20 may be about 100 percent by volume at at least one location within the body 12 along the thickness axis T.
Referring to
In one particular construction, the concentration of the metallic component 18 (
Various materials may be used to form the anti-spalling layer 32 of the disclosed armor panel 30. As one specific, non-limiting example, the anti-spalling layer 32 may be formed from (or may include) high-density polyethylene. As another specific, non-limiting example, the anti-spalling layer 32 may be formed from (or may include) aramid fibers. The cross-sectional thickness of the anti-spalling layer 32 (relative to the thickness axis T′ of the compositionally-graded structure 10′) may be a design consideration, and may vary depending on, for example, the cross-sectional thickness of the compositionally-graded structure 10′.
Referring to
The method 60 may begin at Block 62 with step of materials selection. The materials selection step may include selecting at least one metallic component (in powdered form) and at least one ceramic component (in powdered form) for use in subsequent steps of the method 60. Non-limiting examples of suitable metallic components and suitable ceramic components are disclosed herein. Optionally, the metallic component and the ceramic component may be selected such that a metal element is common to both the metallic component and the ceramic component. For example, the metallic component may be a powdered titanium alloy (e.g., Ti-6Al-4V) and the ceramic component may be a powdered titanium-containing ceramic material, such as titanium diboride, titanium boride and/or titanium carbide.
At Block 64, the metallic component and the ceramic component selected at Block 62 may be used to assemble a powder layup having a plurality of layers of powdered material. In one expression, assembling a powder layup includes laying up at least three layers of powdered material. In another expression, assembling a powder layup includes laying up at least five layers of powdered material. In yet another expression, assembling a powder layup includes laying up at least ten layers of powdered material. Without being limited to any particular theory, it is believed that using a powder layup having a greater number of layers of powdered material may result in a compositionally-graded structure having a smoother transition in composition across the thickness axis.
Adjacent layers (if not all layers) of powdered material of the powder layup may have different compositions, with each layer being formed from the metallic component (unmixed), the ceramic component (unmixed) or by thoroughly mixing (e.g., by shaking, using a rotary ball mixer, or any other mixing procedure) the metallic component and the ceramic component in different ratios. Each layer of the powder layup may include at least one of the metallic component and the ceramic component, wherein the concentration of the metallic component ranges from 0 to 100 percent by volume and the concentration of the ceramic component ranges from 0 to 100 percent by volume.
A non-limiting example powder layup 80 (contained in a die 82) is shown in
At Block 66, the powder layup assembled at Block 64 may be pressed to form a compact that is not yet synthesized. As shown in
Rather than pressing (Block 66) the fully assembled powder layup, one alternative approach to pressing (Block 66) includes pressing each layer of powdered material as it is added to the powder layup. For example, referring to
At this point, those skilled in the art will appreciate that, while assembling the powder layup (Block 64) and pressing (Block 66) are shown in
At Block 68, the compact formed at Block 66 may be heat treated to form a consolidated mass (the compositionally-graded structure). Various heat treatments may be used at Block 68 without departing from the scope of the present disclosure.
In one implementation, the heat treatment step (Block 68) includes hot pressing. The hot pressing process may include one or more consolidating process parameters, such as a consolidating pressure, a consolidating temperature and a consolidating time. The hot pressing process may be performed by any suitable hot pressing apparatus, such as a graphite press, operating under the consolidating process parameters. For example, the compact may be consolidated at the consolidating temperature and under the consolidating pressure for a period of time (e.g., the consolidating time). The hot pressing process may be performed under inert conditions (e.g., argon gas).
Those skilled in the art will appreciate that the hot pressing process consolidating process parameters will depend on the composition of the metallic component and the ceramic component used to form the compact. For example, when a titanium alloy/titanium diboride material system is used, hot pressing (Block 68) may be performed at a temperature ranging from about 800° C. to about 1,400° C. and a pressure ranging from about 40 MPa to about 50 MPa for at least about 30 minutes (e.g., one hour).
In another implementation, the heat treatment step (Block 68) includes hot isostatic pressing (HlPing or HIP consolidating). The hot isostatic pressing process may include one or more consolidating process parameters, such as a consolidating pressure, a consolidating temperature and a consolidating time. The hot isostatic pressing process may be performed by any suitable hot isostatic pressing apparatus operating under the consolidating process parameters. For example, the compact may be consolidated at the consolidating temperature and under the consolidating pressure for a period of time (e.g., the consolidating time). The hot isostatic pressing process may be performed using a commercially available hot isostatic pressing machine.
Those skilled in the art will appreciate that the hot isostatic pressing process consolidating process parameters will depend on the composition of the metallic component and the ceramic component used to form the compact. For example, when a titanium alloy/titanium diboride material system is used, hot isostatic pressing (Block 68) may be performed at a temperature ranging from about 1400° C. to about 1,800° C. and a pressure ranging from about 150 MPa to about 250 MPa for at least about 30 minutes (e.g., one to two hours).
At Block 70, the consolidated mass formed at Block 68 may optionally be subjected to one or more post-processing operations. Examples of post-processing operations include, without limitation, trimming, machining and the like.
Referring to
Accordingly, the disclosed compositionally-graded structure may be suitable for use as (or in) high-energy impact protection apparatus (e.g., armor panels). The continuous transition from primarily ceramic material to primarily metallic material has the potential to slow impact wave propagation, which may provide greater impact energy absorption, thereby reducing the amount (and weight) of material required for high-energy impact protection. Furthermore, the continuous transition from primarily ceramic material to primarily metallic material may offer greater multi-hit performance.
Examples of the disclosure may be described in the context of an aircraft manufacturing and service method 100, as shown in
Each of the processes of method 100 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of venders, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.
As shown in
The disclosed compositionally-graded metal-ceramic structures and methods may be employed during any one or more of the stages of the aircraft manufacturing and service method 100. As one example, components or subassemblies corresponding to component/subassembly manufacturing 108, system integration 110, and or maintenance and service 116 may be fabricated or manufactured using the disclosed compositionally-graded metal-ceramic structures and methods. As another example, the airframe 118 may be constructed using the disclosed compositionally-graded metal-ceramic structures and methods. Also, one or more apparatus examples, method examples, or a combination thereof may be utilized during component/subassembly manufacturing 108 and/or system integration 110, for example, by substantially expediting assembly of or reducing the cost of an aircraft 102, such as the airframe 118 and/or the interior 122. Similarly, one or more of system examples, method examples, or a combination thereof may be utilized while the aircraft 102 is in service, for example and without limitation, to maintenance and service 116.
The disclosed compositionally-graded metal-ceramic structures and methods are described in the context of an aircraft (e.g., helicopters). However, one of ordinary skill in the art will readily recognize that the disclosed compositionally-graded metal-ceramic structures and methods may be utilized for a variety of applications. For example, the disclosed compositionally-graded metal-ceramic structures and methods may be implemented in various types of vehicles including, for example, passenger ships, automobiles, marine products (boats, motors, etc.) and the like. Various non-vehicle applications, such as body armor, are also contemplated.
Although various examples of the disclosed compositionally-graded metal-ceramic structures, armor panels, and methods have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.
