BULLETPROOF LIGHTWEIGHT METAL MATRIX MACROCOMPOSITES WITH CONTROLLED STRUCTURE AND MANUFACTURE THE SAME

• US 20030161750A1
• Filed: 02/28/2002
• Published: 08/28/2003
• Est. Priority Date: 02/28/2002
• Status: Active Grant

• Current Assignee: Advance Materials Products, Inc.
• Original Assignee: Advance Materials Products, Inc.
• Inventors: Moxson, Vladimir S., Ivanov, Eugene
• Granted Patent: US 6,635,357 B2
• Time in Patent Office: Days
• US Class Current: 419/2
• CPC Class Codes: B22F 2998/10 Processes characterised by the sequence of their steps
• CPC Class Codes: B22F 3/04 by applying fluid pressure , e.g. by cold isostatic pressing [CIP]
• CPC Class Codes: B22F 3/15 Hot isostatic pressing
• CPC Class Codes: B22F 3/26 Impregnating making ferrous alloys by impregnation C22C33/0242
• CPC Class Codes: C22C 32/00 Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
• CPC Class Codes: F41H 5/0421 Ceramic layers in combination with metal layers
• CPC Class Codes: Y10T 428/12028 Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
• CPC Class Codes: Y10T 428/12049 Nonmetal component
• CPC Class Codes: Y10T 428/12063 Nonparticulate metal component
• CPC Class Codes: Y10T 428/1216 Continuous interengaged phases of plural metals, or oriented fiber containing
• CPC Class Codes: Y10T 428/12167 Nonmetal containing

Abstract

The lightweight bulletproof metal matrix macrocomposites (MMMC) contain (a) 10-99 vol. % of permeable skeleton structure of titanium, titanium aluminide, Ti-based alloys, and/or mixtures thereof infiltrated with low-melting metal selected from Al, Mg, or their alloys, and (b) 1-90 vol. % of ceramic and/or metal inserts positioned within said skeleton, whereby a normal projection area of each of said inserts is equal to or larger than the cross-section area of a bullet or a projectile body. The MMMC are manufactured as flat or solid-shaped, double-layer, or multi-layer articles containing the same inserts or different inserts in each layer, whereby insert projections of each layer cover spaces between inserts of the underlying layer. The infiltrated metal contains 1-70 wt. % of Al and Mg in the balance, optionally, alloyed with Ti, Si, Zr, Nb, V, as well as with 0-3 wt. % of TiB₂, SiC, or Si₃N₄ sub-micron powders, to promote infiltrating and wetting by Al-containing alloys. The manufacture includes (a) forming the permeable metal powder and inserts into the skeleton-structured preform by positioning inserts in the powder followed by loose sintering in vacuum to provide the average porosity of 20-70%, (b) heating and infiltrating the porous preform with molten infiltrating metal for 10-40 min at 450-750° C., (c) hot isostatic pressing of the infiltrated composite, and (d) re-sintering or diffusion annealing. The positioning of the ceramic inserts in Ti-based powder is carried out by using a metal grid aiding the placement of inserts in a predetermined geometric pattern, and said grid becomes the integral part of the macrocomposite material. The technology is suitable for the manufacture of flat or shaped metal matrix macrocomposites having improved ductility and impact energy absorption such as lightweight bulletproof plates and sheets for airplane, helicopter, and automotive applications.

Claims

1. The lightweight bulletproof metal matrix macrocomposites containing (a) 10-99 vol. % of permeable skeletal structure of titanium, titanium aluminide, titanium-based alloys, and/or mixtures thereof infiltrated with low-melting metal selected from aluminum, magnesium, aluminum-based alloys, and/or magnesium-based alloys, and (b) 1-90 vol. % of ceramic and/or metal inserts positioned within said skeleton, whereby a normal projection area of each inserts is equal to or larger than the cross-section area of a bullet or a projectile body.

2. The lightweight bulletproof metal matrix macrocomposites according to claim 1, wherein inserts are manufactured from the ceramic material selected from the group consisting of oxides, borides, aluminides, carbides, and nitrides, such as alumina, zirconia, yttria stabilized zirconia, silicon carbide, silicon nitride, boron carbide, titanium carbide, cemented carbides, and/or other ceramics or cermets.

3. The lightweight bulletproof metal matrix macrocomposites according to claim 1, wherein inserts are manufactured from the metals selected from the group consisting of titanium, beryllium, aluminum, magnesium, and alloys containing these metals, and/or steels.

4. The lightweight bulletproof metal matrix macrocomposites according to claims 1 and 2, wherein inserts are manufactured from the ceramics reinforced with metal particles and/or fibers.

5. The lightweight bulletproof metal matrix macrocomposites according to claims 1-4 are manufactured as flat or solid shaped, double-layer, or multi-layer articles containing the same inserts or different inserts in each layer, whereby insert projections of each layer cover spaces between inserts of the underlying layer.

6. The lightweight bulletproof metal matrix macrocomposites according to claims 1-5, wherein the infiltrated metal contains 1-70 wt. % of aluminum and magnesium as the balance.

7. The lightweight bulletproof metal matrix macrocomposites according to claims 1-5, wherein the infiltrated metal contains aluminum 1-70 wt. %, at least one metal selected from the group of titanium, silicon, zirconium, niobium, and/or vanadium 1-4 wt. %, and magnesium as the balance.

8. The lightweight bulletproof metal matrix macrocomposites according to claims 6-7, wherein the infiltrated metal additionally contains 0-3 wt. % of at least one dispersed powder selected from TiB₂, SiC, and Si₃N₄ having a particle size of 0.5 μ

m or less, to promote infiltrating and wetting by Al-containing alloys.

9. The lightweight bulletproof metal matrix macrocomposites according to claims 1-8, wherein articles manufactured from said macrocomposites have local porous areas permeable for air.

10. The manufacture of lightweight bulletproof metal matrix macrocomposites according to claims 1-9 includes the steps of:

(a) forming the permeable metal powder and inserts into the skeleton-structured preform by positioning inserts in the powder followed by loose sintering in vacuum, or die pressing, and/or cold isostatic pressing followed by sintering in vacuum or low-pressure sintering in an inert gas, or combinations thereof to provide the average porosity of 20-70%,

(b) heating the obtained porous preform with inserts and infiltrating metal in vacuum or in an inert gas atmosphere up to the infiltration temperature,

(c) infiltrating the porous preform with molten infiltrating metal for 10-40 min at 450-750°

C.,

(d) hot isostatic pressing of the infiltrated composite to heal possible porosity and transform the matrix into the textured microstructure strengthened by intermetallic phases,

(e) re-sintering or diffusion annealing.

11. The manufacture according to claim 10 includes positioning inserts in Ti-base powder or onto loose sintered plate by using a metal grid aiding the placement of the inserts in a predetermined geometrical pattern, filling the gaps between the inserts with a metal powder, and removing the grid.

12. The manufacture according to claim 10 includes positioning of the ceramic inserts in Ti-based powder or onto loose sintered plate by using a metal grid aiding the placement of the inserts in a predetermined geometrical pattern, affixing the grid, filling the gaps between the inserts and the grid with a metal powder, and then, positioning a new layer of inserts onto the first layer with the aid of another metal grid, so that the second layer of inserts projections is placed over the space between the inserts of the first layer, whereby this procedure may be repeated until the desired number of layers is structured into the preform to be infiltrated and sintered with all components including the grids, which become the integral part of the macrocomposite material.

13. The manufacture according to claim 10-12, wherein said inserts have any practical geometrical shape:

balls, cylinders, cubes, plated polygons, etc.

14. The manufacture according to claim 10-13, wherein said layers of the macrocomposire preform contain inserts having different geometrical shape.

15. The manufacture according to claim 10-14, wherein the infiltration of porous preform is carried out spontaneously in vacuum, by a pressure gradient, hot isostatic pressing, hot pressing, or under low pressure of an inert gas.

16. The manufacture according to claim 10-15, wherein a primary metal powder forming said skeletal structure of the macrocomposite preform is selected from Ti-6Al-4V alloy powder, titanium aluminide powder, or a mixture thereof.