Composite material having a layer including entrained particles and method of making same

Abstract

A composite material suitable for use as an armor includes a first layer of a metallic material and a second layer, metallurgically bonded with the first layer. The second layer includes a matrix of the material of the first layer and a plurality of brittle particles dispersed in the matrix. A method for making a composite structure suitable for use as an armor from a workpiece of a metallic material includes the steps of plasticizing a fractional thickness of the workpiece using a friction stir process, introducing a plurality of brittle particles into the plasticized, fractional thickness of the workpiece, and dispersing the plurality of brittle particles into the plasticized, fractional thickness of the workpiece using the friction stir process.

Description

BACKGROUND[0001]1. Field of the Invention[0002]The present invention relates to a composite material. In particular, the present invention relates to a composite material suitable for use as an armor.[0003]2. Description of Related Art[0004]In combat situations, such as in military, police, and / or armored transport operations, it is desirable to protect vehicles, such as tanks, personnel carriers, trucks, and the like, as well as the vehicle's contents from damage by enemy fire. Accordingly, such vehicles are known to have armor to reduce the likelihood that ballistic rounds or other such projectiles will penetrate the vehicle. If the rounds penetrate the vehicle, the occupants of the vehicle may be injured or the vehicle's ability to operate may be impaired. It may also be desirable for the armor to be able to survive multiple rounds striking the armor in close proximity to one another, so that the integrity of the vehicle is not compromised or is only minimally compromised. Moreov...

AI Technical Summary

Benefits of technology

[0012]Therefore, it is an object of the present invention to provide a composite structure that is useful as an armor.

[0016]The present invention provides significant advantages, including: (1) providing a material, useful as an armor, that is lighter in weight than conventional armor; (2) providing a material, useful as an armor, that occupies less volume than conventional armor; (3) providing a material, useful as an armor, that is less expensive to produce than conventional, light-weight armors; and (4) providing a lower-cost means for forming an integral, hard, outer layer on a metallic structure.

Problems solved by technology

If the rounds penetrate the vehicle, the occupants of the vehicle may be injured or the vehicle's ability to operate may be impaired.

Generally, a vehicle's fuel consumption increases as the vehicle's weight increases.

A heavier vehicle usually requires a heavier drive train than a lighter vehicle, which further increases weight.

Increased weight may also reduce the mobility of the vehicle and, thus, reduce the utility of the vehicle in combat.

Many known armor systems, while protecting the vehicle from ballistic damage, add significant weight to the vehicle and provide little or no additional structural strength to the vehicle.

If the size of the vehicle is increased over previous vehicles, the existing transportation equipment may not be capable of transporting the vehicle, or the existing transportation equipment may be limited to carrying fewer vehicles per load.

Accordingly, armor having lower volumes generally result in vehicle designs having larger internal volumes.

Generally, smaller targets (i.e., smaller vehicles) are more difficult to hit with artillery, such as rockets, mortars, missiles, and the like.

During combat and during travel between combat locations, the vehicle may encounter flying rocks, debris, shrapnel, and the like.

If the armor is overly thin or brittle, it may not be capable of surviving impacts from such sources.

Armor that uses exotic materials (e.g., laminated ceramics of boron carbide, silicon carbide, and alumina; fiberglass / epoxy laminates; fiberglass / phenolic laminates; and the like), or armor that has many components in difficult-to-produce configurations, may be quite effective in combat but may be unaffordable.

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