Tailored multilayer material systems and methods for fabrication

Abstract

To provide multilayered material systems tuned to locally meet stringent thermomechanical loading requirements on an extreme environment hypersonic airframe structure.SOLUTION: A graded multilayered composite (1100) comprises a metal matrix material (1110) having a first side (1112) and a second side (1114) opposite the first side (1112). A first layer (1120) of microspheres is dispersed on the first side (1112) of the metal matrix material (1110). A second layer (1122) of microspheres is dispersed on the second side (1114) of the metal matrix material (1110).SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] This application relates to the field of multilayered materials and methods for manufacturing tailored multilayered material systems (TMMS), specifically tailored multilayered material systems for extreme environment supersonic airframe structures (generally including fuselages, wings, wing sections, control surfaces, leading edges, internal structures, air induction systems, and thermal protection systems). [Background technology]

[0002]

[0002] Conventional materials capable of producing manufacturable, durable, and rapidly deployable extreme environment supersonic airframe structures (generally including fuselage, wings, wing sections, control surfaces, leading edges, internal structures, air induction systems, and thermal protection systems) are expensive and require long manufacturing cycles. To provide inexpensive, robust airframe structures and thermal protection systems for future extreme environment applications, new technologies are needed that can produce multi-layer material systems tailored to locally meet stringent thermo-mechanical loading requirements on the airframe.

[0003]

[0003] Accordingly, those skilled in the art continue to conduct research and development efforts in the field of tailored multilayer material systems. Summary of the Invention

[0004] In one embodiment, the gradient multilayer composite comprises a metal matrix material having a first side and a second side opposite the first side, and further includes a first layer of microparticles dispersed on the first side of the metal matrix material and a second layer of microparticles dispersed on the second side of the metal matrix material.

[0005] In another embodiment, the graded multilayer material system includes a non-graded multilayer composite, and the graded multilayer material system further includes at least one graded layer bonded to the non-graded multilayer composite and selected from a graded metal liner, a graded ceramic liner, a graded metal-ceramic hybrid liner, a graded metal core, a graded cooling channel structure, and a graded environmental barrier coating.

[0006] In yet another embodiment, a method for manufacturing a multi-layer material system is provided, the method including providing a gradient multi-layer composite and bonding at least one layer to the gradient multi-layer composite to provide a multi-layer material system.

[0007]

[0008] In yet another embodiment, a method for manufacturing a multi-layer material system is provided, the method including providing a non-graded multi-layer composite and bonding at least one graded layer to the non-graded multi-layer composite to provide the multi-layer material system.

[0008] In one embodiment, the multi-layer material system includes at least one of a liner sheet and a cellular core, and a multi-layer composite (e.g., a multi-layer metal matrix composite) bonded to at least one of the liner sheet and the cellular core, the multi-layer composite including hollow microparticles dispersed within a metal matrix material.

[0009] In another embodiment, a method for manufacturing a multilayer composite includes providing a first layer of a first powder having first hollow microparticles dispersed therein, providing a second layer of a second powder adjacent to the first layer of the first powder, and heating the first layer of the first powder and the second layer of the second powder, the second layer of the second powder having second hollow microparticles dispersed therein.

[0010] In yet another embodiment, a method for manufacturing a multi-layer material system includes providing a first layer of a first powder having first hollow microparticles dispersed therein, providing a second layer of a second powder adjacent to the first layer of the first powder, sintering the first layer of the first powder and the second layer of the second powder, providing at least one of a liner sheet and a cellular core, and bonding the sintered first layer of the first powder with at least one of the liner sheet and the cellular core. The second layer of the second powder has second hollow microparticles dispersed therein.

[0011] Other embodiments of the disclosed multilayer material system and the described method will become apparent from the following detailed description, the accompanying drawings, and the appended claims. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a cross-sectional view of one embodiment of a gradient multilayer composite according to the present description. [Figure 2A] 2 is a cross-sectional view of the graded multilayer composite of FIG. 1 bonded into a single layer structure to form a graded multilayer material system. [Figure 2B] FIG. 1C is a cross-sectional view of a non-graded multilayer composite bonded to a graded single layer structure to form a graded multilayer material system. [Figure 3A] 2 is a cross-sectional view of the graded multilayer composite of FIG. 1 bonded into a multilayer structure to form a graded multilayer material system. [Figure 3B-3E] 3B is a cross-sectional view similar to FIG. 3A showing the graded multilayer composite of FIG. 1 bonded to various multilayer structures to provide various graded multilayer material systems. [Figure 4] FIG. 1 is a flow diagram illustrating a method for manufacturing a multi-layer material system. [Figure 5] FIG. 1 is a flow diagram illustrating a method for manufacturing a multi-layer material system. [Figure 6] FIG. 1 is a perspective view of a vehicle including a multi-layer material system including a cellular sandwich panel and a multi-layer composite bonded to the cellular sandwich panel, in accordance with the present description. [Figure 7]FIG. 7 is a cross-sectional view of one embodiment of the multi-layer material system of FIG. [Figure 8] FIG. 8 is an enlarged cross-sectional view of a portion of the multilayer material system of FIG. [Figure 9] FIG. 7 is a cross-sectional view of another embodiment of the multilayer material system of FIG. [Figure 10] FIG. 10 is an enlarged cross-sectional view of a portion of the multilayer material system of FIG. [Figure 11] FIG. 7 is a flow diagram illustrating a method for manufacturing the multi-layer composite of FIG. 6. [Figure 12] FIG. 7 is a flow diagram illustrating a method for manufacturing the multi-layer material system of FIG. [Figure 13] FIG. 1 is a flow diagram of an aircraft production and service method. [Figure 14] FIG. 1 is a block diagram of an aircraft. DETAILED DESCRIPTION OF THE INVENTION

[0013]

[0028] 1 is a cross-sectional view of one embodiment of a multilayer composite 1100 according to the present description. The multilayer composite 1100 is a gradient multilayer composite including a metal matrix material 1110 having a first side 1112 and a second side 1114 opposite the first side 1112. The gradient multilayer composite 1100 further includes a first layer 1120 of microparticles dispersed on the first side 1112 of the metal matrix material 1110, and a second layer 1122 of microparticles dispersed on the second side 1114 of the metal matrix material 1110.

[0014]

[0029] The multilayer composite 1100 is graded based on a combination of grading factors. As one example, a first portion of the multilayer composite 1100 may have a density that is different from the density of a second portion of the multilayer composite 1100. As another example, the metal matrix material 1110 may include a compositionally graded material (e.g., a hybrid titanium-based and nickel-based material system).

[0015]

[0030] In yet another example, the micro-grains of the first layer of micro-grains 1120 can be spatially dispersed relative to one another based on a first spatial gradient, and the micro-grains of the second layer of micro-grains 1122 can be spatially dispersed relative to one another based on a second spatial gradient different from the first spatial gradient. In an exemplary implementation, the first spatial gradient and the second spatial gradient can be based on the number of micro-grains. In another exemplary implementation, the first spatial gradient and the second spatial gradient can be based on the number of micro-grains. Any combination of other gradient factors and gradient factors associated with the multilayer composite 1100 is possible.

[0016]

[0031] The gradient multilayer composite 1100 further includes a first buffer region 1140 defined between the first layer 1120 of particles and a first edge 1113 of the first side 1112 of the metal matrix material 1110. The gradient multilayer composite 1100 further includes a second buffer region 1142 defined between the second layer 1122 of particles and a second edge 1115 of the second side 1114 of the metal matrix material 1110. The first buffer region 1140 and the second buffer region 1142 are each substantially free of particles. The first buffer region 1140 and the second buffer region 1142 ensure that there are no partial particles near the first edge 1113 and the second edge 1115. The presence of partial particles near the first edge 1113 and the second edge 1115 would result in a weaker force point in the material.

[0017]

[0032] 2A is a cross-sectional view of the graded multilayer composite 1100 of FIG. 1 bonded to a single layer structure 1150 to form a graded multilayer material system 1200. The single layer structure 1150 can be selected from a metal liner (e.g., a monolithic metal, metal alloy, metal matrix composite, intermetallic alloy, intermetallic matrix composite, composite enriched alloy, or composite enriched matrix composite), a ceramic liner (e.g., a monolithic ceramic, ceramic matrix composite, or composite enriched ceramic alloy), a metal-ceramic hybrid liner, a metal core, a cooling channel structure (defining one or more cooling channels), and an environmental barrier coating. The single layer structure 1150 can include a graded material (e.g., a graded metal, a graded ceramic, or a graded hybrid).

[0018]

[0033] Although the graded multilayer material system 1200 of FIG. 2A is formed using the graded multilayer composite 1100 of FIG. 1, it is also contemplated that the graded multilayer material system may be formed using a substantially uniform (i.e., non-graded) multilayer composite, as well as a graded single layer structure, as shown in FIG. 2B.

[0019]

[0034] As shown in FIG. 2B , the multilayer material system 1250 includes a non-graded multilayer composite 1260 (i.e., a substantially homogeneous multilayer composite) bonded to a graded single-layer structure 1280. The non-graded multilayer composite 1260 includes a metal matrix material 1262 having a non-graded layer of micro-grains 1264 dispersed therein. First and second buffer regions 1266, 1268 are disposed on either side of the non-graded layer of micro-grains 1264. The graded single-layer structure 1280 is bonded to the first buffer region 1266.

[0020]

[0035] In some embodiments, non-graded multilayer composite 1260 includes a substantially uniform composition of metal matrix material 1262. In some embodiments, graded single layer structure 1280 is selected from a monolithic or graded metal liner (e.g., a metal, metal alloy, metal matrix composite, intermetallic alloy, intermetallic matrix composite, composite enriched alloy, or composite enriched matrix composite), a monolithic or graded ceramic liner (e.g., a ceramic, ceramic matrix composite, or composite enriched ceramic alloy), a monolithic or graded metal-ceramic hybrid liner, a graded metal core, a graded cooling channel structure (defining one or more cooling channels), and a graded environmental barrier coating.

[0021]

[0036] Figure 3A is a cross-sectional view of the gradient multilayer composite 1100 of Figure 1 bonded to a multilayer structure to form a gradient multilayer material system. Figures 3B through 3E are cross-sectional views similar to Figure 3A, showing the gradient multilayer composite 1100 of Figure 1 bonded to various multilayer structures to provide various gradient multilayer material systems. The various multilayer structures may each include a gradient material structure.

[0022]

[0037] Although the graded multilayer material systems of Figures 3A-3E are each formed using the graded multilayer composite 1100 of Figure 1, it is also contemplated that the multilayer material systems may be formed using substantially uniform (i.e., non-graded) multilayer composites. For purposes of explanation, each of the graded multilayer material systems of Figures 3A-3E will be described using the graded multilayer composite 1100 of Figure 1.

[0023]

[0038] As shown in the gradient multilayer material system 1300a in FIG. 3A, the gradient multilayer composite 1100a is sandwiched between a cooling channel structure 1310a (defining one or more cooling channels 1311a) and a first liner sheet 1320a. This sandwiched structure is then sandwiched between an environmental barrier coating 1330a and a cellular core 1340a. A second liner sheet 1350a is disposed on the opposite side of the cellular core 1340a. The environmental barrier coating 1330a can include a monolithic or graded metallic material (e.g., a metal, metal alloy, metal matrix composite, intermetallic alloy, intermetallic matrix composite, composite enriched alloy, or composite enriched matrix composite), a monolithic or graded ceramic material (e.g., a ceramic, ceramic matrix composite, or composite enriched ceramic alloy), or a monolithic or graded graded metal-ceramic hybrid material. This environmental barrier coating 1330a may be provided for oxidation resistance, corrosion resistance, wear resistance, increased emissivity, and the like.

[0024]

[0039] As shown in the graded multilayer material system 1300b in Figure 3B, the graded multilayer composite 1100b is sandwiched between a cooling channel structure 1310b (defining one or more cooling channels 1311b) and a first liner sheet 1320b. An environmental barrier coating 1330b is disposed on the opposite side of the cooling channel structure 1310b.

[0025]

[0040] As shown in the gradient multilayer material system 1300c in FIG. 3C, the gradient multilayer composite 1100c is integrated with a cooling channel structure 1310c (defining one or more cooling channels 1311c). This integrated structure is sandwiched between a first liner sheet 1320c and a second liner sheet 1350c. The first liner sheet 1320c and the second liner sheet 1350c can comprise a monolithic or graded metallic material (e.g., a metal, metal alloy, metal matrix composite, intermetallic alloy, intermetallic matrix composite, composite enriched alloy, or composite enriched matrix composite), a monolithic or graded ceramic material (e.g., a ceramic, ceramic matrix composite, or composite enriched ceramic alloy), or a monolithic or graded graded metal-ceramic hybrid material. An environmental barrier coating 1330c is disposed on the opposite side of the first liner sheet 1320c.

[0026]

[0041] As shown in the graded multilayer material system 1300f in Figure 3D, the graded multilayer composite 1100f is sandwiched between a cooling channel structure 1310f (defining one or more cooling channels 1311f) and an environmental barrier coating 1330f. A cellular core 1340f is disposed on the opposite side of the cooling channel structure 1310f. A liner sheet 1320f is disposed on the opposite side of the cellular core 1340f.

[0027]

[0042] As shown in the gradient multilayer material system 1300g in FIG. 3E, the gradient multilayer composite 1100g is integrated with a cooling channel structure 1310g (defining one or more cooling channels 1311g). This integrated structure is sandwiched between a first liner sheet 1320g and a second liner sheet 1350g. This sandwiched structure is then sandwiched between a first cellular core 1340g and a second cellular core 1360g. This sandwiched structure is then sandwiched between a third liner sheet 1370g and a fourth liner sheet 1380g. An environmental barrier coating 1330g is disposed on the opposite side of the third liner sheet 1370g.

[0028]

[0043] 3A-3E, it is contemplated that any number of individual elements and any combination of elements may be used to provide a graded multilayer material system. Additionally, it is contemplated that a multilayer composite may be integrated with any of the elements.

[0029]

[0044] 4, a flow diagram 1400 depicts a method for manufacturing a multi-layer material system. At block 1410, a gradient multi-layer composite is provided. The process then proceeds to block 1420. At block 1420, at least one layer is bonded to the gradient multi-layer composite to provide a multi-layer material system. The process then ends.

[0030]

[0045] In some embodiments, at least one layer is selected from a monolithic or graded metal liner (e.g., a metal, metal alloy, metal matrix composite, intermetallic alloy, intermetallic matrix composite, composite enriched alloy, or composite enriched matrix composite), a monolithic or graded ceramic liner (e.g., a ceramic, ceramic matrix composite, or composite enriched ceramic alloy), a monolithic or graded metal-ceramic hybrid liner, a monolithic or graded metal core, a monolithic or graded cooling channel structure, or a monolithic or graded environmental barrier coating. For example, the monolithic or graded metal liner comprises a metal, metal alloy, metal matrix composite, intermetallic alloy, intermetallic matrix composite, composite enriched alloy, or composite enriched matrix composite, and the monolithic or graded ceramic liner comprises a ceramic, ceramic matrix composite, or composite enriched ceramic alloy.

[0031]

[0046] 5, flow diagram 1500 depicts a method for fabricating a tailored multi-layer material system. At block 1510, a non-graded multi-layer composite is provided. The process then proceeds to block 1520, where at least one monolithic or graded layer is bonded to the non-graded multi-layer composite to provide a tailored multi-layer material system. The process then ends.

[0032]

[0047] In some embodiments, the at least one graded layer is selected from a graded metal liner, a graded ceramic liner, a graded metal-ceramic hybrid liner, a graded metal core, a graded cooling channel structure, and a graded environmental barrier coating. For example, a monolithic or graded metal liner comprises a metal, a metal alloy, a metal matrix composite, an intermetallic alloy, an intermetallic matrix composite, a composite enriched alloy, or a composite enriched matrix composite, and a monolithic or graded ceramic liner comprises a ceramic, a ceramic matrix composite, or a composite enriched ceramic alloy.

[0033]

[0048] 6 is a perspective view of a structure 1 including a multi-layer material system 10 in accordance with the present description. While structure 1 depicts an aircraft (e.g., a hypersonic aircraft), structure 1 is not limited to vehicles and may include, for example, a weapon (e.g., a hypersonic weapon). Multi-layer material system 10 forms the exterior surface of structure 1 and may function as a thermal protection system for structure 1. Furthermore, multi-layer material system 10 may further function as an integrated thermal protection system for other large area skin structure structures, engine inlet structures, leading edge structures, control surface structures, thermo-mechanical isolator structures, or internally cooled components.

[0034]

[0049] Figure 7 is a cross-sectional view of an example of the multi-layer material system 10 of Figure 6, and Figure 8 is an enlarged cross-sectional view of a portion of the multi-layer material system of Figure 7. As shown in Figures 7 and 8, the prepared multi-layer material system 10 includes a cellular sandwich panel 100 and a multi-layer composite 200 bonded to the cellular sandwich panel 100, the multi-layer composite 200 including hollow microparticles 210 dispersed within a metal matrix material 220.

[0035]

[0050] Figure 9 is a cross-sectional view of another example of the multi-layer material system 10 of Figure 6, and Figure 10 is an enlarged cross-sectional view of a portion of the prepared multi-layer material system of Figure 9. As shown in Figures 9 and 10, the multi-layer material system 10 includes a cellular sandwich panel 100 and a multi-layer composite 200 bonded to the cellular sandwich panel 100, the multi-layer composite 200 including a spatial distribution of hollow microparticles 210 dispersed within a metal matrix material 220.

[0036]

[0051] The multi-layer material system 10 of Figures 7-10 enables the design of multi-functional, tunable structures that combine exceptional stiffness and strength-to-weight ratios with additional functional enhancements (e.g., thermal protection and management). The multi-layer material system 10 includes two main components. First, the cellular sandwich panel 100 can be optimized and tailored to meet specific extreme environment application requirements. Second, the multi-layer composite 200 can be optimized and tailored to meet thermo-mechanical loading profile requirements. Furthermore, the cellular sandwich panel 100 and the multi-layer composite 200 can be bonded together in a variety of ways to meet the thermo-mechanical loading requirements.

[0037]

[0052] In one embodiment, the cellular sandwich panel 100 includes a first liner sheet 110, a second liner sheet 120, and a cellular core 130 between the first liner sheet 110 and the second liner sheet 120. The thickness of the cellular core 130 is typically greater than the thickness of the first liner sheet 110 and the second liner sheet 120, and the density of the cellular core 130 is typically less than the density of the first liner sheet 110 and the second liner sheet 120. The stiffness of the first liner sheet 110 and the second liner sheet 120 is typically greater than the stiffness of the cellular core 130. By attaching the thinner but stiffer first liner sheet 110 and the second liner sheet 120 to the lighter but thicker cellular core 130, the cellular sandwich panel 100 has a high stiffness and an overall low density.

[0038]

[0053] The first liner sheet 110 can be formed from a variety of alloys, including, but not limited to, aluminum and aluminum alloy / metal matrix composites, titanium and titanium alloy / metal matrix composites, superalloys (iron and iron alloy / metal matrix composites, nickel and nickel alloy / metal matrix composites, cobalt and cobalt alloy / metal matrix composites), refractory metals and alloys / metal matrix composites, copper and copper alloy / metal matrix composites, precious metals and alloys / metal matrix composites, zirconium and hafnium and their alloys / metal matrix composites, intermetallic compounds, complex-enriched alloy / metal matrix composites (high-entropy alloy / metal matrix composites, intermediate-entropy alloy / metal matrix composites, multi-component alloy / metal matrix composites). In one embodiment, the first liner sheet 110 is formed from a titanium alloy. The first liner sheet 110 can be optimized and tailored to have a variety of thicknesses.

[0039]

[0054] The second liner sheet 120 can be formed from a variety of alloys, including, but not limited to, aluminum and aluminum alloy / metal matrix composites, titanium and titanium alloy / metal matrix composites, superalloys (iron and iron alloy / metal matrix composites, nickel and nickel alloy / metal matrix composites, cobalt and cobalt alloy / metal matrix composites), refractory metals and alloys / metal matrix composites, copper and copper alloy / metal matrix composites, precious metals and alloys / metal matrix composites, zirconium and hafnium and their alloys / metal matrix composites, intermetallic compounds, complex-enriched alloy / metal matrix composites (high-entropy alloy / metal matrix composites, intermediate-entropy alloy / metal matrix composites, multi-component alloy / metal matrix composites). In one embodiment, the second liner sheet 120 is formed from a titanium alloy. The second liner sheet 120 can be optimized and tailored to have a variety of thicknesses.

[0040]

[0055] The cellular core 130 can be formed from a variety of alloys, including, but not limited to, aluminum and aluminum alloy / metal matrix composites, titanium and titanium alloy / metal matrix composites, superalloys (iron and iron alloy / metal matrix composites, nickel and nickel alloy / metal matrix composites, cobalt and cobalt alloy / metal matrix composites), refractory metals and alloys / metal matrix composites, copper and copper alloy / metal matrix composites, precious metals and alloys / metal matrix composites, zirconium and hafnium and their alloys / metal matrix composites, intermetallic compounds, complex enriched alloy / metal matrix composites (high entropy alloy / metal matrix composites, intermediate entropy alloy / metal matrix composites, multi-component alloy / metal matrix composites). In one embodiment, the cellular core 130 is formed from a titanium alloy. The cellular core 130 can be optimized and tailored to have a variety of thicknesses.

[0041]

[0056] The cellular core 130 can be produced using a variety of additive manufacturing techniques, including melt processes (e.g., powder bed fusion or directed energy deposition), sintering processes (e.g., binder jetting, material extrusion, and material jetting), solid-state processes (e.g., additive friction stir processes, ultrasonic additive processes, cold spray, etc.).

[0042]

[0057] The cellular core 130 may have a variety of structures. In one embodiment, the cellular core 130 may have an open cellular structure. In another embodiment, the cellular core 130 may have a closed cellular structure. In another embodiment, the cellular core 130 may have a honeycomb structure. The structure of the cellular core 130 can be tailored and optimized to meet application requirements.

[0043]

[0058] The cellular core 130 can be joined to the first liner sheet 110 and the second liner sheet 120 by various methods (e.g., welding, brazing, fastening, diffusion bonding (with or without an intermediate foil / coating), or additive manufacturing).

[0044]

[0059] In one embodiment, the cellular core 130 includes one or more third liner sheets. In another embodiment, the cellular core 130 includes one or more third liner sheets 132 that are superplastically formed and diffusion bonded to the first liner sheet 110 and the second liner sheet 120. Superplastic forming and diffusion bonding (SPF / DB) is a technique for forming hollow cellular sandwich panels with complex shapes. Superplastic forming and diffusion bonding are combined to produce cellular sandwich panels. Typically, three or more metal sheets are welded together at their edges and heated within the confines of a female mold tool. At high temperatures, the three or more liner sheets become extremely malleable (i.e., superplastic). When in the superplastic state, an inert gas is injected between the three or more liner sheets to form them into the shape of the mold. Superplastic forming and diffusion bonding are useful for complex shapes. Therefore, the structure of the one or more third linersheets 132 of the cellular core 130 can be adjusted and optimized to meet a wide range of application requirements. In an exemplary embodiment, the cellular core 130 includes a double core structure having two third linersheets 132.

[0045]

[0060] The cellular sandwich panel 100 can provide thermal protection gradient functionality. In one embodiment, the melting point and thermal microstructural stability point of the first linersheet 110 are higher than the melting point and thermal microstructural stability point of the second linersheet 120. In another embodiment, the melting point and thermal microstructural stability point of the first linersheet 110 are higher than the melting point and thermal microstructural stability point of the cellular core 130. In yet another embodiment, the melting point and thermal microstructural stability point of the cellular core 130 are higher than the melting point and thermal microstructural stability point of the second linersheet 120. In yet another embodiment, the melting point and thermal microstructural stability point of the first linersheet 110 are higher than the melting point and thermal microstructural stability point of the cellular core 130, which are higher than the melting point and thermal microstructural stability point of the second linersheet 110. By providing the thermally protective grading described above, the cellular sandwich panel 100 has a hot side that is more resistant to high temperatures and a cold side that is less resistant to high temperatures.

[0046]

[0061] Furthermore, by relaxing the requirement for high temperature resistance on the cold side, the cold side can be formed from a material that has lower cost or superior properties (e.g., increased strength, increased damage tolerance, increased resistance to environmental cracking, increased formability, increased bondability, or increased reproducibility) than the material on the hot side. Thus, for example, the strength, damage tolerance, environmental cracking resistance, formability, bondability, or reproducibility of the second linersheet 120 is greater than the strength, damage tolerance, environmental cracking resistance, formability, bondability, or reproducibility of the first linersheet 110. As another example, the strength, damage tolerance, environmental cracking resistance, formability, bondability, or reproducibility of the second linersheet 120 is greater than the strength, damage tolerance, environmental cracking resistance, formability, bondability, or reproducibility of the cellular core 130. In yet another embodiment, the strength, damage tolerance, environmental crack resistance, formability, bondability, or reproducibility of the cellular core 130 is greater than the strength, damage tolerance, environmental crack resistance, formability, bondability, or reproducibility of the first linersheet 110. In yet another embodiment, the strength, damage tolerance, environmental crack resistance, formability, bondability, or reproducibility of the second linersheet 120 is greater than the strength, damage tolerance, environmental crack resistance, formability, bondability, or reproducibility of the cellular core 130, and these properties of the cellular core 130 are greater than the strength, damage tolerance, environmental crack resistance, formability, bondability, or reproducibility of the first linersheet 110. By providing the thermally protective gradient functionality described above, the cellular sandwich panel 100 may have a hot side that is more resistant to high temperatures but has less strength, damage tolerance, environmental crack resistance, formability, bondability, or reproducibility, and a cold side that is less resistant to high temperatures but has more strength, damage tolerance, environmental crack resistance, formability, bondability, or reproducibility.

[0047]

[0062] The first liner sheet 110 may include a first liner layer 112 adjacent to the cellular core 130 and a second liner layer 114 adjacent to the multilayer composite 200. The first liner layer 112 and the second liner layer 114 may provide thermally protective gradient functionality. In one embodiment, the melting point or thermal microstructural stability point of the second liner sheet 114 is higher than the melting point or thermal microstructural stability point of the first liner sheet 112. The first liner sheet 110 may further include a third or additional liner layer intermediate the first liner layer 112 and the second liner layer 114. The third or additional liner layer has a melting point or thermal microstructural stability point approximately intermediate between the first liner layer 112 and the second liner layer 114. By providing the above-described thermal protective gradient functionality of the first linersheet 110, the first linersheet 110 has a hot side that is more resistant to high temperatures and a cold side that is less resistant to high temperatures.

[0048]

[0063] The first liner sheet 110 may provide compatibility with the multilayer composite 200. In one embodiment, the first liner layer 112 is compatible with the second liner layer 114, which is compatible with the multilayer composite 200, but the first liner layer 112 is incompatible or has low compatibility with the multilayer composite 200. The first liner sheet 110 may further include a third or additional liner layer intermediate the first liner layer 112 and the second liner layer 114. The third or additional liner layer is compatible with the first liner layer 112 and the second liner layer 114, but the first liner layer 112 and the second liner layer 114 are incompatible or have low compatibility with each other.

[0049]

[0064] In one embodiment, the composition of the first liner layer 112 includes elements that are detrimental to the properties of the multi-layer composite 200, or the composition of the multi-layer composite 200 includes elements that are detrimental to the properties of the first liner layer 112, and the second liner layer 114 removes the detrimental elements. Thus, the first liner sheet 110 can provide improved compatibility between the cellular sandwich panel 100 and the multi-layer composite 200.

[0050]

[0065] In another example, the temperature at which the multi-layer composite 200 is processed exceeds the melting point or thermal microstructural stability point of the first liner layer 112, resulting in incompatibility between the first liner layer 112 and the multi-layer composite 200, and the melting point or thermal microstructural stability point of the second liner layer 114 exceeds the temperature at which the multi-layer composite 200 is processed, resulting in improved compatibility between the second liner layer 114 and the multi-layer composite 200. The temperature at which the multi-layer composite 200 is processed may include, for example, a bonding temperature, a sintering temperature, or a heat treatment temperature. Thus, the first liner sheet 110 can provide improved compatibility between the cellular sandwich panel 100 and the multi-layer composite 200.

[0051]

[0066] In yet another embodiment, the coefficient of thermal expansion of the first liner layer 112 is significantly different from the coefficient of thermal expansion of the multi-layer composite 200, and the coefficient of thermal expansion of the second liner layer 114 is not significantly different from the coefficient of thermal expansion of the multi-layer composite 200. Thus, the first liner sheet 110 can provide improved compatibility between the cellular sandwich panel 100 and the multi-layer composite 200.

[0052]

[0067] Additionally, the first liner layer 112 can be formed from an alloy with lower cost or superior properties (e.g., increased strength, damage tolerance, environmental crack resistance, formability, bondability, or reproducibility). Thus, for example, the strength, damage tolerance, environmental crack resistance, formability, bondability, or reproducibility of the first liner sheet 112 is greater than the strength, damage tolerance, environmental crack resistance, formability, bondability, or reproducibility of the second liner sheet 114. Thus, by providing the compatibility described above between the cellular sandwich panel 100 and the multilayer composite 200, the cellular sandwich panel 100 can maintain compatibility with the multilayer composite 200 while providing greater overall strength, damage tolerance, environmental crack resistance, formability, bondability, or reproducibility.

[0053]

[0068] As described above, the multi-layer composite 200 includes hollow microparticles 210 dispersed within a metal matrix material 220. The hollow microparticles 210 provide lightweight, insulating, conductive, and / or noise / impact attenuation properties to the multi-layer composite 200. The metal matrix material 220 can provide durability and failure resistance to the multi-layer composite 200.

[0054]

[0069] The metal matrix material 220 can be formed from a variety of materials. In one embodiment, the metal matrix material 220 is formed from at least one of alloy materials, including, but not limited to, aluminum and aluminum alloy / metal matrix composites, titanium and titanium alloy / metal matrix composites, superalloys (iron and iron alloy / metal matrix composites, nickel and nickel alloy / metal matrix composites, cobalt and cobalt alloy / metal matrix composites), refractory metals and alloys / metal matrix composites, copper and copper alloy / metal matrix composites, precious metals and alloys / metal matrix composites, zirconium and hafnium and their alloys / metal matrix composites, intermetallic compounds, complex-enriched alloy / metal matrix composites (high-entropy alloy / metal matrix composites, intermediate-entropy alloy / metal matrix composites, multi-component alloy / metal matrix composites), and ceramic materials. Forming the metal matrix material 220 from at least one of an alloy material and a ceramic material can provide the metal matrix material 220 with high temperature resistance. In a particular embodiment, the metallic matrix material 220 is formed from a nickel-based superalloy. In another particular embodiment, the metallic matrix material is formed from a titanium-based superalloy.

[0055]

[0070] The hollow microparticles 210 can be formed from a variety of materials. In one embodiment, the hollow microparticles 210 are formed from a ceramic material. Forming the hollow microparticles 210 from a ceramic material provides the hollow microparticles 210 with high temperature resistance, resistance to deformation, and the ability to maintain the shape of their hollow interior periphery. In certain embodiments, the ceramic material is formed from yttria-stabilized zirconia or alumina-silica-iron glass. The structure of the hollow microparticles 210 can be tailored and optimized to enable the multilayer composite 200 to meet application requirements. This structure includes the material, coating size, shell thickness, coating thickness, and type / material. In some implementations, the material of the hollow microparticles 210 is ceramic-based or metal-based, and ranges in size from 5 microns to 500 microns in diameter with an average wall thickness of 2% to 30% of the diameter. In some implementations, the hollow microparticles 210 are made from a metal, ceramic, or hybrid metal-ceramic material combination and are coated with a coating having a coating thickness between 2 microns and 200 microns. The microparticles may also be solid. These exemplary implementations tailor the multilayer composite 200 for specific applications.

[0056]

[0071] In one embodiment, the hollow microparticles 210 are contained within the metal matrix material 220 at a volume fraction ranging from approximately 1 to 60 percent. The volume fraction of the hollow microparticles 210 is defined as the volume of all hollow microparticles 210 within the metal matrix material 220 divided by the total volume of the hollow microparticles 210 and the metal matrix material 220. A higher volume fraction of the hollow microparticles 210 increases the lightweight, insulating, conductive, and / or noise / impact damping properties of the multilayer composite 200. A lower volume fraction of the hollow microparticles 210 increases the durability and failure resistance of the multilayer composite 200.

[0057]

[0072] In one embodiment, the multilayer composite 200 includes a first layer 202 adjacent to the first linersheet 110 and a second layer 204 adjacent to the first layer 202. The first layer 202 has a first matrix 222 including first hollow microparticles 212, and the second layer 204 has a second matrix 224 including second hollow microparticles 214.

[0058]

[0073] First layer 202 and second layer 204 may provide thermally protective functional gradients. In one embodiment, the melting point or thermal microstructural stability point of second matrix 224 is higher than the melting point or thermal microstructural stability point of first matrix 222. Multilayer composite 200 may further include a third or additional layer intermediate first layer 202 and second layer 204. The third or additional layer has a matrix with a melting point or thermal microstructural stability point intermediate between the melting points or thermal microstructural stability points of first matrix 222 and second matrix 224. By providing the thermally protective functional gradients described above for multilayer composite 200, multilayer composite 200 has a high-temperature side that is more resistant to high temperatures and a low-temperature side that is less resistant to high temperatures.

[0059]

[0074] The multilayer composite 200 may be compatible with the cellular sandwich panel 100. In one embodiment, the first matrix 222 is compatible with the second liner layer 114 of the cellular sandwich panel 100, while the second matrix 224 is incompatible or has low compatibility with the second liner layer 114 of the cellular sandwich panel 100. The multilayer composite 200 may further include a third or additional layer intermediate the first layer 202 and the second layer 204. The third or additional layer is compatible with the first layer 202 and the second layer 204, while the first layer 202 and the second layer 204 are incompatible or have low compatibility with each other.

[0060]

[0075] In one embodiment, the composition of the second matrix 224 includes elements that are detrimental to the properties of the second liner layer 114, or the composition of the second liner layer 114 includes elements that are detrimental to the properties of the second matrix 224, and the second matrix 224 removes the detrimental elements. Thus, the multilayer composite 200 can provide improved compatibility with the cellular sandwich panel 100.

[0061]

[0076] In another example, the temperature at which the second matrix 224 is treated exceeds the melting point or thermal microstructural stability point of the second liner layer 114, resulting in incompatibility between the second matrix 224 and the second liner layer 114, and the melting point or thermal microstructural stability point of the second liner layer 114 exceeds the temperature at which the first matrix 222 is treated, resulting in improved compatibility between the first matrix 222 and the second liner layer 114. The temperature at which the first matrix 222 and the first matrix 224 are treated may include, for example, a bonding temperature, a sintering temperature, or a heat treatment temperature. Thus, the multilayer composite 200 may provide improved compatibility with the cellular sandwich panel 100.

[0062]

[0077] In yet another embodiment, the coefficient of thermal expansion of the second layer 204 is significantly different from the coefficient of thermal expansion of the second liner layer 114, and the coefficient of thermal expansion of the first layer 202 is not significantly different from the coefficient of thermal expansion of the second liner layer 114. Thus, the multilayer composite 200 can provide improved compatibility with the cellular sandwich panel 100.

[0063]

[0078] Furthermore, the second matrix 224 may be formed from a material with low cost or superior properties (e.g., higher resistance to high temperatures). Thus, as an example, the melting point or thermal microstructural stabilization point of the second matrix 224 is higher than the melting point or thermal microstructural stabilization point of the first matrix 222. Thus, by achieving the above-described compatibility between the multilayer composite 200 and the cellular sandwich panel 100, the multilayer composite 200 can maintain compatibility with the cellular sandwich panel 100 while having higher resistance to high temperatures.

[0064]

[0079] 9 and 10, the first layer 202 and the second layer 204 provide a spatial distribution of hollow microparticles 210. Although Figures 9 and 10 show the first layer 202 and the second layer 204 as providing a gradient spatial distribution of the hollow microparticles 210, it is also possible that the first layer 202 and the second layer 204 provide a substantially uniform (i.e., non-gradient) spatial distribution of the hollow microparticles 210. For purposes of explanation, only the gradient spatial distribution of the hollow microparticles 210 will be described herein.

[0065]

[0080] 9 and 10 , the volume fraction of the second hollow microparticles 214 in the second layer 204 is greater than the volume fraction of the first hollow microparticles 212 in the first layer 202. For example, the volume fraction of the second hollow microparticles 214 in the second layer 204 is at least 5 percent greater, preferably at least 10 percent greater, more preferably at least 20 percent greater, even more preferably at least 50 percent greater, and even more preferably at least 100 percent greater than the volume fraction of the first hollow microparticles 212 in the first layer 202. Thus, the first layer 202 may have greater durability and resistance to failure, while the second layer 204 may have an overall lower density and may have greater insulating, conductive, and / or noise / impact attenuation properties. Furthermore, a first layer 202 having a lower volume fraction of first hollow microparticles 212 may be more compatible with bonding to the second liner layer 114 than a second layer 204 having a higher volume fraction of second hollow microparticles 214. In a specific example, the first layer 202 has a volume fraction of first hollow microparticles 212 of about 10%, and the second layer 204 has a volume fraction of second hollow microparticles 214 of about 45%. The first liner sheet 110 may further include a third or additional liner layer intermediate the first and second liner layers 112, 114. The third or additional liner layer has a melting point or thermal microstructural stability point that is intermediate between the first and second liner layers 112, 114. The multilayer composite 200 may further include a third or additional layer intermediate the first and second layers 202, 204. The third or further layer has third or further hollow microparticles with a different volume fraction of hollow microparticles.

[0066]

[0081] 9 and 10 show the first layer 202 covering a surface of the cellular sandwich panel 100, the second layer 204 covering a surface of the first layer 202, and the first layer 202 and second layer 204 having generally flat layers, other configurations of the first layer 202 and second layer 204 are also encompassed by this description. For example, the first layer 202 and the second layer 204 each cover adjacent portions of the cellular sandwich panel 100. Thus, the first layer 202 may be more compatible with fastening to the second liner layer 114 of the cellular sandwich panel 100 than the second layer 204. Thus, the first layer 202 may be positioned over the second liner layer 114. Fasteners connect the second liner layer 114 to the multilayer composite 200.

[0067]

[0082] In another example, the composition of the second hollow microparticles 214 in the second layer 204 is different from the composition of the first hollow microparticles 212 in the first layer 202. For example, the composition of the second hollow microparticles 214 is selected to provide insulating, conductive, and / or noise / impact damping properties that are greater than the insulating, conductive, and / or noise / impact damping properties of the composition of the first hollow microparticles 212. Thus, the first layer 202 can have different properties (e.g., insulating, conductive, and / or noise / impact damping properties) compared to the second layer 204.

[0068]

[0083] In yet another example, the size of the second hollow microparticles 214 in the second layer 204 is different from the size of the first hollow microparticles 212 in the first layer 202. Thus, the first layer 202 may have different insulating, conductive, and / or noise / impact attenuation properties compared to the second layer 204.

[0069]

[0084] 7-10, the multi-layer material system 10 further includes a barrier coating 300 on the surface of the multi-layer composite 200 to protect against environmental exposure and increase emissivity. The barrier coating 300 can have a variety of structures, compositions, and thicknesses.

[0070]

[0085] The cellular sandwich panel 100 and the multi-layer composite 200 may be joined in a variety of ways to form the joint 400. Exemplary methods include welding, brazing, diffusion bonding, and fastening. In particular embodiments, the cellular sandwich panel 100 and the multi-layer composite 200 are joined using a compositionally graded braze joint to form the joint 400. In one embodiment, the compositionally graded braze joint includes a first braze layer adjacent to the cellular sandwich panel 100 and a second braze layer adjacent to the multi-layer composite 200, the first braze layer having a coefficient of thermal expansion that matches the cellular sandwich panel 100, and the second braze layer having a coefficient of thermal expansion that matches the multi-layer composite 200. Additionally, the compositionally graded braze joint may include a third or additional braze layer intermediate the first and second braze layers. The third or further brazing layer has a coefficient of thermal expansion intermediate the coefficients of thermal expansion of the first and second brazing layers, and thus the compositionally graded brazing joint can accommodate the mismatch in the coefficients of thermal expansion between the cellular sandwich panel 100 and the multilayer composite 200.

[0071]

[0086] Although the multi-layer material system 10 is shown in a flat configuration, the overall shape of the multi-layer material system 10 may vary. For example, curved or complex curved surfaces of large area skin structures, engine inlet structures, leading edge structures, control surface structures, thermo-mechanical isolator structures, or integrated thermal protection systems for internally cooled components may be formed from the multi-layer material system 10.

[0072]

[0087] 11 is a flow diagram illustrating a method 600 for manufacturing the multilayer composite 200 of FIG. 6. The method 600 includes, at block 610, providing a first layer of a first powder having first hollow microparticles dispersed therein, and at block 620, providing a second layer of a second powder adjacent to the first layer of the first powder, the second layer of the second powder having second hollow microparticles 214 dispersed therein. The method 600 further includes, at block 630, heating the first layer of the first powder and the second layer of the second powder. The heating can be performed under various levels of sustained stress and for various durations.

[0073]

[0088] In one embodiment, the melting point or thermal microstructural stability point of the second layer of the second powder is higher than the melting point or thermal microstructural stability point of the first layer of the first powder. Thus, the multilayer composite 200 may be provided with thermally protective functional grading, as described above.

[0074]

[0089] In another example, the volume fraction of hollow microparticles in the second layer of the second powder is greater than the volume fraction of hollow microparticles in the first layer of the first powder. Thus, the multilayer composite 200 may be provided with a graded spatial distribution of hollow microparticles 210 dispersed within the metal matrix material 220, as described above.

[0075]

[0090] The first layer of the first powder with the first hollow microparticles 212 dispersed therein and the second layer of the second powder with the second hollow microparticles 214 dispersed therein can be provided in various ways. In one example, the first hollow microparticles 212 and the second hollow microparticles 214 are premixed into the first powder and the second powder, respectively. In another example, the first powder is provided as a first layer in the tool, and then the first hollow microparticles 212 are placed within the first layer. The second powder is provided as a second layer in the tool, and then the second hollow microparticles 214 are placed within the second layer.

[0076]

[0091] The second layer of the second powder can be disposed adjacent to the first layer of the first powder in a variety of ways. In one example, the first layer of the first powder is applied to a tool and then pressed with or without heat. The second layer of the second powder is then applied to the tool over the first layer and then pressed or heated together with the first layer of the first powder. In another example, the first layer of the first powder is applied to a tool and then an interlayer material (e.g., an interlayer foil or interlayer mesh) is applied over the first layer. The second layer of the second powder is then applied to the tool over the interlayer material and heated together with the first layer of the first powder and the interlayer material. In yet another example, an interlayer barrier is applied to the mold to separate the first and second compartments. A first layer of a first powder is provided in a first compartment, a second layer of a second powder is provided in a second compartment, and then the first and second layers, together with the interlayer barrier, are heated. Thus, the first layer of the first powder and the second layer of the second powder can be positioned adjacent to each other in a variety of ways.

[0077]

[0092] In one example, heating the first layer of the first powder and the second layer of the second powder includes heating the first layer of the first powder and the second layer of the second powder to a sintering temperature. Heating can include a consolidation process (e.g., hot isostatic pressing, spark plasma sintering, or cold isostatic pressing and sintering). In another example, heating the first layer of the first powder and the second layer of the second powder includes heating the first layer of the first powder and the second layer of the second powder to a heat treatment temperature.

[0078]

[0093] In one embodiment, the first layer or the second layer is sintered, consolidated, or heat-treated before the other of the first layer or the second layer is applied. For example, the second layer of the second powder can have a processing temperature (e.g., a sintering temperature, a consolidation temperature, or a heat-treatment temperature) higher than the melting point or thermal microstructural stability point of the first layer of the first powder. Thus, the second layer of the second powder can be processed before applying the first layer of the first powder, and then the first layer of the first powder can be subjected to processing (e.g., sintering, consolidation, or heat treatment). Thus, by separately processing the first layer of the first powder and the second layer of the second powder, the multilayer composite 200 can be provided with thermally protective gradient functionality as described above.

[0079]

[0094] FIG. 12 is a flow diagram illustrating a method 700 for manufacturing the multilayer material system 10 of FIG. 6. The method 700 includes, at block 710, providing a first layer of a first powder having first hollow micro-particles 212 dispersed therein; at block 720, providing a second layer of a second powder adjacent to the first layer of the first powder, the second layer of the second powder having second hollow micro-particles 214 dispersed therein; and at block 730, sintering the first layer of the first powder and the second layer of the second powder. The method 700 also includes, at block 740, providing at least one of a liner sheet and a cellular core; and, at block 750, bonding the sintered first layer of the first powder to at least one of the liner sheet and the cellular core. In some implementations, the first layer of the first powder and the second layer of the second powder are sintered under a required stress for a required period of time.

[0080]

[0095] In one embodiment, the melting point or thermal microstructural stability point of the second layer of the second powder is higher than the melting point or thermal microstructural stability point of the first layer of the first powder. Thus, the multilayer composite 200 may be provided with thermally protective functional grading, as described above.

[0081]

[0096] In another example, the volume fraction of hollow microparticles in the second layer of the second powder is greater than the volume fraction of hollow microparticles in the first layer of the first powder. Thus, the multilayer composite 200 may be provided with a graded spatial distribution of hollow microparticles 210 dispersed within the metal matrix material 220, as described above.

[0082]

[0097] The first layer of the first powder with the first hollow microparticles 212 dispersed therein and the second layer of the second powder with the second hollow microparticles 214 dispersed therein can be provided in various ways. In one example, the first hollow microparticles 212 and the second hollow microparticles 214 are premixed into the first powder and the second powder, respectively. In another example, the first powder is provided as a first layer in the tool, and then the first hollow microparticles 212 are placed within the first layer. The second powder is provided as a second layer in the tool, and then the second hollow microparticles 214 are placed within the second layer.

[0083]

[0098] The second layer of the second powder can be disposed adjacent to the first layer of the first powder in a variety of ways. In one example, the first layer of the first powder is applied to a tool and then pressed with or without heat. The second layer of the second powder is then applied to the tool over the first layer and then pressed or heated together with the first layer of the first powder. In another example, the first layer of the first powder is applied to a tool and then an interlayer material (e.g., an interlayer foil or interlayer mesh) is applied over the first layer. The second layer of the second powder is then applied to the tool over the interlayer material and heated together with the first layer of the first powder and the interlayer material. In yet another example, an interlayer barrier is applied to the mold to separate the first and second compartments. A first layer of a first powder is provided in a first compartment, a second layer of a second powder is provided in a second compartment, and then the first and second layers, together with the interlayer barrier, are heated. Thus, the first layer of the first powder and the second layer of the second powder can be positioned adjacent to each other in a variety of ways.

[0084]

[0099] In one example, sintering the first layer of the first powder and the second layer of the second powder can include a consolidation process (e.g., hot isostatic pressing, spark plasma sintering, or cold isostatic pressing and sintering).

[0085]

[0100] In one embodiment, the first layer or the second layer is sintered before the other of the first layer or the second layer is applied. For example, the second layer of the second powder may have a sintering temperature higher than the melting point or thermal microstructural stability point of the first layer of the first powder. Thus, the second layer of the second powder may be sintered before applying the first layer of the first powder, which may then be sintered. Thus, by separately processing the first layer of the first powder and the second layer of the second powder, the multilayer composite 200 may be provided with a thermally protective gradient function, as described above.

[0086]

[0101] The cellular sandwich panel 100 may take a variety of forms and may be formed according to a variety of methods, as described above. In one example, providing at least one of a liner sheet and a cellular core includes, at block 742, providing a first liner sheet 110, and, at block 744, providing a second liner sheet 120. Providing at least one of a liner sheet and a cellular core further includes, at block 746, providing one or more third liner sheets 132 between the first liner sheet 110 and the second liner sheet 120, and, at block 748, superplastically forming and diffusion bonding the one or more third liner sheets to the first liner sheet and the second liner sheet.

[0087]

[0102] Bonding the first layer of sintered first powder to at least one of the liner sheet and the cellular core can be performed by various methods. Exemplary methods include welding, brazing, diffusion bonding, and fastening. In certain embodiments, the at least one of the liner sheet and the cellular core and the multilayer composite 200 are joined using a compositionally graded braze joint to form the joint 400. In one embodiment, bonding the first layer of sintered first powder to at least one of the liner sheet and the cellular core includes providing a first braze layer adjacent to the at least one of the liner sheet and the cellular core and providing a second braze layer adjacent to the multilayer composite 200. The first braze layer can have a coefficient of thermal expansion that matches the cellular sandwich panel 100, and the second braze layer can have a coefficient of thermal expansion that matches the multilayer composite 200. Additionally, the compositionally graded braze joint can include a third or additional braze layer intermediate the first and second braze layers, the third or additional braze layer having a coefficient of thermal expansion intermediate the coefficients of thermal expansion of the first and second braze layers. Thus, the compositionally graded braze joint can accommodate a mismatch in the coefficient of thermal expansion between at least one of the liner sheet and the cellular core and the multilayer composite 200.

[0088]

[0103] Additionally, illustrative and non-exhaustive examples of the subject matter encompassed herein are provided below.

[0089]

[0104] A gradient multilayer composite (1100) comprising a metal matrix material (1110) having a first side (1112) and a second side (1114) opposite the first side (1112), a first layer (1120) of microparticles dispersed on the first side (1112) of the metal matrix material (1110), and a second layer (1122) of microparticles dispersed on the second side (1114) of the metal matrix material (1110).

[0090]

[0105] The gradient multilayer composite 1100 of the immediately preceding paragraph, wherein a density of a first portion of the gradient multilayer composite is different from a density of a second portion of the gradient multilayer composite.

[0091]

[0106] The gradient multilayer composite 1100 of either of the two immediately preceding paragraphs, wherein the metal matrix material 1110 comprises a compositionally gradient material.

[0092]

[0107] The gradient multilayer composite 1100 of the immediately preceding paragraph, wherein the composition of the metal matrix material 1110 comprises at least one of aluminum, aluminum alloy / metal matrix composite, titanium, titanium alloy / metal matrix composite, iron, iron alloy / metal matrix composite, nickel, nickel alloy / metal matrix composite, cobalt, cobalt alloy / metal matrix composite, refractory metal, refractory metal alloy / metal matrix composite, copper, copper alloy / metal matrix composite, precious metal, precious metal alloy / metal matrix composite, zirconium, zirconium alloy / metal matrix composite, hafnium, hafnium alloy / metal matrix composite, and an intermetallic compound.

[0093]

[0108] A gradient multilayer composite 1100 described in any of the four immediately preceding paragraphs, wherein (i) the micrograins of the first layer 1120 of micrograins are spatially dispersed relative to each other based on a first spatial gradient, and (ii) the micrograins of the second layer 1122 of micrograins are spatially dispersed relative to each other based on a second spatial gradient different from the first spatial gradient.

[0094]

[0109] The gradient multilayer composite 1100 described in the immediately preceding paragraph further includes a first buffer region 1140 defined between the first layer 1120 of micrograins and a first edge 1113 of the first side 1112 of the metal matrix material 1110, and a second buffer region 1142 defined between the second layer 1122 of micrograins and a second edge 1115 of the second side 1114 of the metal matrix material 1110, wherein the first buffer region 1140 and the second buffer region 1142 are each substantially free of micrograins.

[0095]

[0110] The gradient multilayer composite 1100 of either of the two immediately preceding paragraphs, wherein the first spatial gradient and the second spatial gradient are based on the number of micrograins.

[0096]

[0111] The gradient multilayer composite 1100 described in any of the first two of the three immediately preceding paragraphs, wherein the first spatial gradient and the second spatial gradient are based on the size of the micrograins.

[0097]

[0112] A gradient multilayer composite 1100 described in any of the eight immediately preceding paragraphs, wherein (i) the density of a first portion of the gradient multilayer composite is different from the density of a second portion of the gradient multilayer composite, (ii) the metal matrix material 1110 comprises a compositionally gradient material, (iii) the micro-grains of the first layer 1120 of micro-grains are spatially dispersed relative to each other based on a first spatial gradient, and (iv) the micro-grains of the second layer 1122 of micro-grains are spatially dispersed relative to each other based on a second spatial gradient that is different from the first spatial gradient.

[0098]

[0113] The gradient multilayer composite 1100 described in the immediately preceding paragraph further includes a first buffer region 1140 defined between the first layer 1120 of micrograins and a first edge 1113 of the first side 1112 of the metal matrix material 1110, and a second buffer region 1142 defined between the second layer 1122 of micrograins and a second edge 1115 of the second side 1114 of the metal matrix material 1110, wherein the first buffer region 1140 and the second buffer region 1142 are each substantially free of micrograins.

[0099]

[0114] ] A multilayer material system 1200 comprising a gradient multilayer composite 1100 described in any one of the immediately preceding 10 paragraphs, and a layer 1150 bonded to the non-graded multilayer composite 1100 and selected from a monolithic or gradient metal liner, a monolithic or gradient ceramic liner, a monolithic or gradient metal-ceramic hybrid liner, a monolithic or gradient metal core, a monolithic or gradient cooling channel structure, or a monolithic or gradient environmental barrier coating.

[0100]

[0115] The multi-layer material system 1200 of the immediately preceding paragraph, wherein the layer 1150 includes at least one graded layer.

[0101]

[0116] A method for manufacturing a multi-layer material system 1200 described in any one of the two immediately preceding paragraphs, comprising bonding the layer 1150 to the gradient multi-layer composite 1100 to provide the multi-layer material system 1200.

[0102]

[0117] The method of the immediately preceding paragraph, wherein the layer 1150 is selected from a monolithic or graded metal liner, a monolithic or graded ceramic liner, a monolithic or graded metal-ceramic hybrid liner, a monolithic or graded metal core, a monolithic or graded cooling channel structure, or a monolithic or graded environmental barrier coating.

[0103]

[0118] A multilayer material system 1250 comprising a non-graded multilayer composite 1260 and at least one layer 1280 bonded to the non-graded multilayer composite 1260 and selected from a monolithic or graded metal liner, a monolithic or graded ceramic liner, a monolithic or graded metal-ceramic hybrid liner, a monolithic or graded metal core, a monolithic or graded cooling channel structure, or a monolithic or graded environmental barrier coating.

[0104]

[0119] The multi-layer material system 1250 of the immediately preceding paragraph, wherein the non-graded multi-layer composite 1260 includes a non-graded layer 1264 of micro-grains.

[0105]

[0120] The multi-layer material system 1250 of either of the two immediately preceding paragraphs, wherein the non-graded multi-layer composite 1260 comprises a substantially uniform composition of metal matrix material 1262 within the multi-layer composite.

[0106]

[0121] The multilayer material system 1250 described in the first of the three immediately preceding paragraphs, wherein the non-graded multilayer composite 1260 includes a metal matrix material 1262 having a non-graded layer 1264 of microparticles dispersed in the metal matrix material 1262.

[0107]

[0122] 1. A method for manufacturing a multi-layer material system, the method comprising: providing a non-graded multi-layer composite; and bonding at least one graded layer to the non-graded multi-layer composite to provide the multi-layer material system.

[0108]

[0123] The method of the immediately preceding paragraph, wherein the at least one graded layer is selected from a monolithic or graded metal liner, a monolithic or graded ceramic liner, a monolithic or graded metal-ceramic hybrid liner, a monolithic or graded metal core, a monolithic or graded cooling channel structure, or a monolithic or graded environmental barrier coating.

[0109]

[0124] The above description includes numerous materials. It should be understood that "metal / metallic" includes "metal and metal matrix composites," "ceramic" includes "ceramic and ceramic matrix composites," and "hybrid metal-ceramic" includes "metal-ceramic hybrids and metal matrix composite / ceramic matrix composite hybrids." Furthermore, metal-based includes aluminum and aluminum alloy / metal matrix composites, titanium and titanium alloy / metal matrix composites, superalloys (iron and iron alloy / metal matrix composites, nickel and nickel alloy / metal matrix composites, cobalt and cobalt alloy / metal matrix composites), refractory metals and alloys / metal matrix composites, copper and copper alloy / metal matrix composites, precious metals and alloys / metal matrix composites, zirconium and hafnium and their alloys / metal matrix composites, intermetallic compounds, complex concentrated alloy / metal matrix composites (high entropy alloy / metal matrix composites, intermediate entropy alloy / metal matrix composites, multi-component alloy / metal matrix composites).

[0110]

[0125] The graded multilayer composite 1100 of FIG. 1, the graded multilayer material system 1200 of FIG. 2, the multilayer material systems 1300a-1300g of FIGS. 3A-3E, and the multilayer material system 10 of FIGS. 7-10 disclosed herein each comprise either a tailored multilayer composite or a multilayer material system capable of performing under stringent thermomechanical loading requirements (e.g., on an aircraft).

[0111]

[0126] Embodiments of the disclosure may be described with reference to an aircraft manufacturing and service method 1000 shown in Figure 13 and an aircraft 1002 shown in Figure 14. The aircraft manufacturing and service method 1000 may include, during a pre-production phase, specification and design 1004 of the aircraft 1002 and material procurement 1006. During production, component / subassembly manufacturing 1008 and system integration 1010 of the aircraft 1002 occurs. The aircraft 1002 may then undergo certification and delivery 1012 before being placed into service 1014. While in customer operation, the aircraft 1002 is scheduled for routine maintenance and service 1016, which may include modification, reconfiguration, refurbishment, etc.

[0112]

[0127] Each process of method 1000 may be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). For purposes of this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors, a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers, and an operator may be an airline, a leasing company, a military organization, a service organization, etc.

[0113]

[0128] Any combination of the graded multilayer composite 1100 of FIG. 1 , the graded multilayer material system 1200 of FIG. 2 , the multilayer material systems 1300 a - 1300 g of FIGS. 3A-3E , and the multilayer material system 10 of FIGS. 7-10 may be utilized during any one or more of the stages of an aircraft manufacturing and service method 1000 (including specification and design 1004 of the aircraft 1002, material procurement 1006, component / subassembly manufacturing 1008, system integration 1010, certification and delivery 1012, placing the aircraft into service 1014, and routine maintenance and service 1016).

[0114]

[0129] 14 , an aircraft 1002 produced by exemplary method 1000 may include an airframe 1018 with a number of systems 1020 and an interior 1022. Examples of the number of systems 1020 may include one or more of a propulsion system 1024, an electrical system 1026, a hydraulic system 1028, and an environmental system 1030. Any number of other systems may be included. The multi-layer material system 10 of the present disclosure may be utilized in any system of the aircraft 1002.

[0115]

[0130] While various embodiments of the disclosed multi-layer material systems and multi-layer composites have been shown and described, modifications will occur to those skilled in the art upon reading this specification, and the present application includes such modifications and is limited only by the scope of the claims.

Claims

1. a metal matrix material (1110) having a first side (1112) and a second side (1114) opposite the first side (1112); a first layer (1120) of microparticles dispersed on the first side (1112) of the metal matrix material (1110); and a second layer (1122) of microparticles dispersed on the second side (1114) of the metal matrix material (1110); Including, (i) the microparticles of the first layer (1120) of microparticles are spatially dispersed relative to one another based on a first spatial gradient, and (ii) the microparticles of the second layer (1122) of microparticles are spatially dispersed relative to one another based on a second spatial gradient different from the first spatial gradient; a first buffer region (1140) defined between the first layer (1120) of micro-grains and a first edge (1113) of the first side (1112) of the metal matrix material (1110); and a second buffer region (1142) defined between the second layer (1122) of micro-grains and a second edge (1115) of the second side (1114) of the metal matrix material (1110); further comprising A gradient multilayer composite (1100), wherein the first buffer region (1140) and the second buffer region (1142) are each free of micrograins.

2. The gradient multi-layer composite (1100) of claim 1, wherein a density of a first portion of the gradient multi-layer composite is different from a density of a second portion of the gradient multi-layer composite.

3. The gradient multilayer composite (1100) of claim 1 or 2, wherein the metal matrix material (1110) comprises a compositionally gradient material.

4. 4. The gradient multilayer composite of claim 3, wherein the composition of the metal matrix material comprises at least one of aluminum, aluminum alloy / metal matrix composite, titanium, titanium alloy / metal matrix composite, iron, iron alloy / metal matrix composite, nickel, nickel alloy / metal matrix composite, cobalt, cobalt alloy / metal matrix composite, refractory metal, refractory metal alloy / metal matrix composite, copper, copper alloy / metal matrix composite, noble metal, noble metal alloy / metal matrix composite, zirconium, zirconium alloy / metal matrix composite, hafnium, hafnium alloy / metal matrix composite, and an intermetallic compound.

5. The gradient multilayer composite (1100) of claim 1, wherein the first spatial gradient and the second spatial gradient are based on a number of micrograins.

6. The gradient multilayer composite (1100) of claim 1, wherein the first spatial gradient and the second spatial gradient are based on a size of a micrograin.

7. 7. A gradient multilayer composite (1100) according to any one of claims 1 to 6, wherein: (i) the density of a first portion of the gradient multilayer composite is different from the density of a second portion of the gradient multilayer composite; (ii) the metal matrix material (1110) comprises a compositionally gradient material; (iii) the micro-grains of the first layer (1120) of micro-grains are spatially dispersed relative to one another based on a first spatial gradient; and (iv) the micro-grains of the second layer (1122) of micro-grains are spatially dispersed relative to one another based on a second spatial gradient different from the first spatial gradient.

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