Tuned multilayer material systems and manufacturing methods

Abstract

The present disclosure relates to tuned multilayer material systems and manufacturing methods. A graded multilayer composite (1100) includes a metal matrix material (1110) having a first side (1112) and a second side (1114) opposite the first side (1112). A first microsphere layer (1120) is dispersed on the first side (1112) of the metal matrix material (1110). A second microsphere layer (1122) is dispersed on the second side (1114) of the metal matrix material (1110).

Description

Technical Field

[0001] The present application relates to the field of multilayer materials and methods for manufacturing tuned multilayer material systems (TMMS), and in particular, to tuned multilayer material systems for extreme environment hypersonic aircraft airframe structures that generally include fuselage, wings, tail, control surfaces, leading edges, internal structures, air induction systems and thermal protection systems. Background Art

[0002] Conventional materials capable of providing a path to manufacturable, durable and rapidly deployable extreme environment hypersonic aircraft airframe structures, generally including fuselage, wings, tail, control surfaces, leading edges, internal structures and air induction systems, are expensive and require long manufacturing cycles. To provide affordable and robust aircraft airframe structures and thermal protection systems for future extreme environment applications, new technologies are needed that can provide multilayer material systems that are tuned to locally meet the stringent thermomechanical load requirements on the aircraft fuselage.

[0003] Accordingly, those skilled in the art have been conducting research and development in the area of ​​tuned multilayer material systems. Summary of the invention

[0004] In one example, a graded multilayer composite includes a metal matrix material having a first side and a second side opposite the first side. The graded multilayer composite also includes a first microsphere layer dispersed on the first side of the metal matrix material and a second microsphere layer dispersed on the second side of the metal matrix material.

[0005] In another example, a graded multilayer material system includes a non-graded multilayer composite. The graded multilayer material system also includes at least one graded layer, the at least one graded layer being joined to the non-graded multilayer composite and being 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 example, a method of manufacturing a multi-layer material system is provided. The method includes providing a graded multi-layer composite and bonding at least one layer to the graded multi-layer composite to provide the multi-layer material system.

[0007] In yet another example, a method of manufacturing a multi-layer material system is provided. The method includes 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 example, the multilayer material system includes at least one of a liner sheet and a honeycomb core and a multilayer composite (eg, a multilayer metal matrix composite) bonded to the at least one of the liner sheet and the honeycomb core. The multilayer composite includes hollow microspheres dispersed in a metal matrix material.

[0009] In another example, a method of making a multilayer composite includes providing a first layer of a first powder having first hollow microspheres 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 has second hollow microspheres dispersed therein.

[0010] In yet another example, a method of manufacturing a multilayer material system includes: providing a first layer of a first powder, wherein the first layer of the first powder has first hollow microspheres 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 honeycomb core; and bonding the sintered first layer of the first powder to at least one of the liner sheet and the honeycomb core. The second layer of the second powder has second hollow microspheres dispersed therein.

[0011] Other examples of the multi-layer material systems and methods disclosed in this specification will become apparent from the following detailed description, accompanying drawings, and appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a cross-sectional view of an example of a graded, multi-layer composite according to the present description.

[0013] Figure 2A is joined to a single layer structure to form a graded multilayer material system Figure 1 Cross-sectional view of a graded multilayer composite.

[0014] Figure 2B is a cross-sectional view of a non-hierarchical multilayer composite being joined to a hierarchical single-layer structure to form a hierarchical multilayer material system.

[0015] Figure 3A is joined to a multilayer structure to form a graded multilayer material system Figure 1 Cross-sectional view of a graded multilayer composite.

[0016] FIG. 3B to FIG. 3E is with Figure 3A Similar cross-sectional views and showing the multi-layer material system being joined to different multi-layer structures to provide different grades Figure 1 A graded multi-layer composite.

[0017] Figure 4is a flow chart representing a method for manufacturing a multi-layer material system.

[0018] Figure 5 is a flow chart representing a method for manufacturing a multi-layer material system.

[0019] Figure 6 is a perspective view of a vehicle according to the present specification including a multilayer material system including a honeycomb sandwich panel and a multilayer composite joined to the honeycomb sandwich panel.

[0020] Figure 7 yes Figure 6 A cross-sectional view of an example of a multilayer material system.

[0021] Figure 8 yes Figure 7 An enlarged cross-sectional view of a portion of a multilayer material system.

[0022] Fig. 9 yes Figure 6 A cross-sectional view of another example of a multilayer material system.

[0023] Fig.10 yes Fig. 9 An enlarged cross-sectional view of a portion of a multilayer material system.

[0024] Fig.11 It means used for manufacturing Figure 6 Flowchart of a method for producing a multilayer composite.

[0025] Fig.12 It means used for manufacturing Figure 6 Flowchart of a method for a multilayer material system.

[0026] Fig.13 It is a flow chart of the aircraft manufacturing and maintenance methods.

[0027] Fig.14 This is a block diagram of an aircraft. DETAILED DESCRIPTION

[0028] Figure 1 1 is a cross-sectional view of an example of a multilayer composite 1100 according to the present specification. Multilayer composite 1100 is a graded multilayer composite including a metal matrix material 1110 having a first side 1112 and a second side 1114 opposite first side 1112. Graded multilayer composite 1100 also includes a first microsphere layer 1120 dispersed on first side 1112 of metal matrix material 1110 and a second microsphere layer 1122 dispersed on second side 1114 of metal matrix material 1110.

[0029] The multi-layer composite 1100 is graded based on a combination of graded factors. As an example, a first portion of the multi-layer composite 1100 may have a density that is different than a density of a second portion of the multi-layer composite 1100. As another example, the metal matrix material 1110 may include a compositionally graded material, such as a mixed titanium-based and nickel-based material system.

[0030] As yet another example, the microspheres in the first microsphere layer 1120 may be spatially distributed relative to each other based on a first spatial gradient, and the microspheres in the second microsphere layer 1122 may be spatially distributed relative to each other based on a second spatial gradient, the second spatial gradient being different from the first spatial gradient. In an example implementation, the first spatial gradient and the second spatial gradient may be based on the number of microspheres. In another example implementation, the first spatial gradient and the second spatial gradient may be based on the size of the microspheres. Other grading factors and any combination of grading factors associated with the multilayer composite 1100 are possible.

[0031] The graded multi-layer composite 1100 also includes a first buffer region 1140 defined between the first microsphere layer 1120 and the first edge 1113 of the first side 1112 of the metal matrix material 1110. The graded multi-layer composite 1100 also includes a second buffer region 1142 defined between the second microsphere layer 1122 and the second edge 1115 of the second side 1114 of the metal matrix material 1110. Each of the first buffer region 1140 and the second buffer region 1142 is substantially free of microspheres. The first buffer region 1140 and the second buffer region 1142 ensure that there are no partial microspheres near the first edge 1113 and the second edge 1115 that may cause a weak material stress point.

[0032] Figure 2A is joined to the single layer structure 1150 to form a graded multilayer material system 1200 Figure 1 100. The single layer structure 1150 may be selected from a metal liner (e.g., a monolithic metal, a metal alloy, a metal matrix composite, an intermetallic alloy, an intermetallic matrix composite, a composite condensed alloy, or a composite condensed matrix composite), a ceramic liner (e.g., a monolithic ceramic, a ceramic matrix composite, or a composite condensed 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 may include a graded material (e.g., a graded metal or a graded ceramic or a graded mixture).

[0033] although Figure 2A The graded multilayer material system 1200 is used Figure 1Although the hierarchical multilayer composite 1100 is formed, it is contemplated that a hierarchical multilayer composite and a hierarchical single layer structure may be used to form a hierarchical multilayer material system, such as Figure 2B as shown in .

[0034] like Figure 2B , the multilayer material system 1250 includes a non-graded multilayer composite 1260 (i.e., a substantially uniform multilayer composite) bonded to a graded monolayer structure 1280. The non-graded multilayer composite 1260 includes a metal matrix material 1262 having a non-graded microsphere layer 1264 dispersed therein. A first buffer region 1266 and a second buffer region 1268 are disposed on opposite sides of the non-graded microsphere layer 1264. The graded monolayer structure 1280 is bonded to the first buffer region 1266.

[0035] In some examples, the non-graded multilayer composite 1260 includes a substantially uniform composition of a metal matrix material 1262. In some examples, the graded single layer structure 1280 is selected from a monolithic or graded metal liner (e.g., a metal, a metal alloy, a metal matrix composite, an intermetallic alloy, an intermetallic matrix composite, a composite condensed alloy, or a composite condensed matrix composite), a monolithic or graded ceramic liner (e.g., a ceramic, a ceramic matrix composite, or a complex condensed ceramic alloy), or 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.

[0036] Figure 3A is joined to a multilayer structure to form a graded multilayer material system Figure 1 A cross-sectional view of a graded multi-layer composite 1100 is shown. FIG. 3B to FIG. 3E Each of these is Figure 3A Similar cross-sectional views and showing the multi-layer material system joined to different multi-layer structures to provide different grades Figure 1 The graded multi-layer composite 1100. Each of the different multi-layer structures may include a graded material structure.

[0037] although FIG. 3A to FIG. 3E Each of the hierarchical multi-layer material systems is used Figure 1 The multilayer composite 1100 is formed of a graded multilayer composite 1100, but it is contemplated that a substantially uniform (ie, non-graded) multilayer composite may be used to form a multilayer material system. For purposes of illustration, Figure 1 The graded multilayer composite 1100 is described FIG. 3A to FIG. 3E Each of the hierarchical multi-layer material systems.

[0038] like Figure 3AAs shown in the hierarchical multilayer material system 1300a, the hierarchical multilayer composite 1100a is sandwiched between a cooling channel structure 1310a (defining one or more cooling channels 1311a) and a first liner sheet 1320a. The sandwich structure is further sandwiched between an environmental barrier coating 1330a and a honeycomb core 1340a. A second liner sheet 1350a is disposed on the other side of the honeycomb core 1340a. The environmental barrier coating 1330a may include an integral or hierarchical metal material (e.g., a metal, a metal alloy, a metal matrix composite, an intermetallic alloy, an intermetallic matrix composite, a complex condensed alloy, or a complex condensed matrix composite), an integral or hierarchical ceramic material (e.g., a ceramic, a ceramic matrix composite, or a complex condensed ceramic alloy), or an integral or hierarchical metal-ceramic hybrid material. The environmental barrier coating 1330a may be provided for oxidation resistance, corrosion resistance, wear resistance, increased emissivity, etc.

[0039] like Figure 3B As shown in the graded multilayer material system 1300b, 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 other side of the cooling channel structure 1310b.

[0040] like Figure 3C As shown in the hierarchical multilayer material system 1300c, the hierarchical multilayer composite 1100c is integrated with a cooling channel structure 1310c (defining one or more cooling channels 1311c). The 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 may include an integral or hierarchical metal material (e.g., a metal, a metal alloy, a metal matrix composite, an intermetallic alloy, an intermetallic matrix composite, a complex concentrated alloy, or a complex concentrated matrix composite), an integral or hierarchical ceramic material (e.g., a ceramic, a ceramic matrix composite, or a complex concentrated ceramic alloy), or an integral or hierarchical metal-ceramic hybrid material. An environmental barrier coating 1330c is disposed on the other side of the first liner sheet 1320c.

[0041] like Figure 3D As shown in the graded multilayer material system 1300f, 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 honeycomb core 1340f is disposed on the other side of the cooling channel structure 1310f. A liner sheet 1320f is disposed on the other side of the honeycomb core 1340f.

[0042] like Figure 3EAs shown in the hierarchical multilayer material system 1300g, the hierarchical multilayer composite 1100g is integrated with a cooling channel structure 1310g (defining one or more cooling channels 1311g). The integrated structure is sandwiched between the first liner sheet 1320g and the second liner sheet 1350g. The sandwich structure is further sandwiched between the first honeycomb core 1340g and the second honeycomb core 1360g. The sandwich structure is further sandwiched between the third liner sheet 1370g and the fourth liner sheet 1380g. The environmental barrier coating 1330g is disposed on the opposite side of the third liner sheet 1370g.

[0043] exist FIG. 3A to FIG. 3E In each of the above, it is contemplated that any number of individual components and any combination of components may be used to provide a hierarchical multilayer material system. In addition, it is contemplated that the multilayer composite may be integrated with any component.

[0044] Reference Figure 4 , flow chart 1400 represents a method for manufacturing a multi-layer material system. In block 1410, a graded multi-layer composite is provided. The process proceeds to block 1420, in which at least one layer is joined to the graded multi-layer composite to provide a multi-layer material system. The process then ends.

[0045] In some examples, the at least one layer is selected from a monolithic or graded metal liner (e.g., a metal, a metal alloy, a metal matrix composite, an intermetallic alloy, an intermetallic matrix composite, a complex concentrated alloy, or a complex concentrated matrix composite), a monolithic or graded ceramic liner (e.g., a ceramic, a ceramic matrix composite, or a complex concentrated ceramic alloy), or 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 includes a metal, a metal alloy, a metal matrix composite, an intermetallic alloy, an intermetallic matrix composite, a complex concentrated alloy, or a complex concentrated matrix composite, and the monolithic or graded ceramic liner includes a ceramic, a ceramic matrix composite, or a complex concentrated ceramic alloy.

[0046] Reference Figure 5 , flow chart 1500 represents a method for manufacturing a tuned multilayer material system. In block 1510, a non-graded multilayer composite is provided. The process proceeds to block 1520, in which at least one integral layer or graded layer is bonded to the non-graded multilayer composite to provide a tuned multilayer material system. The process then ends.

[0047] In some examples, 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, the monolithic or graded metal liner includes a metal, a metal alloy, a metal matrix composite, an intermetallic alloy, an intermetallic matrix composite, a complex condensed alloy, or a complex condensed matrix composite, and the monolithic or graded ceramic liner includes a ceramic, a ceramic matrix composite, or a complex condensed ceramic alloy.

[0048] Figure 6 1 is a perspective view of a structure 1 including a multilayer material system 10 according to the present specification. The illustrated structure 1 is an aircraft such as a hypersonic aircraft, but the structure 1 is not limited to vehicles and may include, for example, a weapon such as a hypersonic weapon. The multilayer material system 10 may form an outer surface of the structure 1 and may be used as a thermal protection system for the structure 1. It may also be used as other area skin structures, engine air inlet structures, leading edge structures, control surface structures, thermomechanical isolator structures, or integrated thermal protection systems for internal cold components.

[0049] Figure 7 yes Figure 6 A cross-sectional view of an example of a multilayer material system 10, Figure 8 yes Figure 7 An enlarged cross-sectional view of a portion of a multilayer material system. Figure 7 and Figure 8 As shown in , the tuned multilayer material system 10 includes a honeycomb sandwich panel 100 and a multilayer composite 200 bonded to the honeycomb sandwich panel 100 , wherein the multilayer composite 200 includes hollow microspheres 210 dispersed in a metal matrix material 220 .

[0050] Fig. 9 yes Figure 6 A cross-sectional view of another example of a multilayer material system 10, and Fig.10 yes Fig. 9 A magnified cross-sectional view of a portion of a tuned multilayer material system. Fig. 9 and Fig.10 As shown in , the multilayer material system 10 includes a honeycomb sandwich panel 100 and a multilayer composite 200 bonded to the honeycomb sandwich panel 100 , wherein the multilayer composite 200 includes a spatial distribution of hollow microspheres 210 dispersed within a metal matrix material 220 .

[0051] Figures 7 to 10The multilayer material system 10 enables the design of versatile and tunable structures that combine excellent stiffness and strength-to-weight ratios with additional functional enhancements such as thermal protection and thermal management. The multilayer material system 10 includes two main components. First, the honeycomb sandwich panel 100 can be optimized and tuned to meet specific extreme environment application requirements. Second, the multilayer composite 200 can be optimized and tuned to meet thermomechanical load distribution requirements. In addition, the honeycomb sandwich panel 100 and the multilayer composite 200 can be joined together by various methods to meet thermomechanical load requirements.

[0052] In an example, the honeycomb sandwich panel 100 includes a first lining sheet 110, a second lining sheet 120, and a honeycomb core 130 between the first lining sheet 110 and the second lining sheet 120. The thickness of the honeycomb core 130 is generally greater than the thickness of the first lining sheet 110 and the second lining sheet 120, and the density of the honeycomb core 130 is generally less than the density of the first lining sheet 110 and the second lining sheet 120. The stiffness of the first lining sheet 110 and the second lining sheet 120 is generally greater than the stiffness of the honeycomb core 130. By attaching the thinner but stiffer first lining sheet 110 and the second lining sheet 120 to the lightweight and thicker honeycomb core 130, the honeycomb sandwich panel 100 is provided with high stiffness and low overall density.

[0053] The first liner sheet 110 may be formed of a variety of alloys, including but not limited to: aluminum and aluminum alloys / metal matrix composites; titanium and titanium alloys / metal matrix composites; super alloys (including iron and iron alloys / metal matrix composites, nickel and nickel alloys / metal matrix composites, cobalt and cobalt alloys / metal matrix composites); refractory metals and alloys / metal matrix composites; copper and copper alloys / metal matrix composites; precious metals and alloys / metal matrix composites; zirconium and hafnium and their alloys / metal matrix composites; intermetallic substances; complex concentrated alloys / metal matrix composites (high entropy alloys / metal matrix composites, medium entropy alloys / metal matrix composites, multi-component alloys / metal matrix composites). In an example, the first liner sheet 110 is formed of a titanium alloy. The first liner sheet 110 may be optimized and tuned to have various thicknesses.

[0054] The second liner sheet 120 may be formed of a variety of alloys, including but not limited to: aluminum and aluminum alloys / metal matrix composites; titanium and titanium alloys / metal matrix composites; super alloys (including iron and iron alloys / metal matrix composites, nickel and nickel alloys / metal matrix composites, cobalt and cobalt alloys / metal matrix composites); refractory metals and alloys / metal matrix composites; copper and copper alloys / metal matrix composites; precious metals and alloys / metal matrix composites; zirconium and hafnium and their alloys / metal matrix composites; intermetallic substances; complex concentrated alloys / metal matrix composites (high entropy alloys / metal matrix composites, medium entropy alloys / metal matrix composites, multi-component alloys / metal matrix composites). In an example, the second liner sheet 120 is formed of a titanium alloy. The second liner sheet 120 may be optimized and tuned to have various thicknesses.

[0055] The honeycomb core 130 may be formed of a variety of alloys, including but not limited to: aluminum and aluminum alloys / metal matrix composites; titanium and titanium alloys / metal matrix composites; super alloys (including iron and iron alloys / metal matrix composites, nickel and nickel alloys / metal matrix composites, cobalt and cobalt alloys / metal matrix composites); refractory metals and alloys / metal matrix composites; copper and copper alloys / metal matrix composites; precious metals and alloys / metal matrix composites; zirconium and hafnium and their alloys / metal matrix composites; intermetallic substances; complex concentrated alloys / metal matrix composites (high entropy alloys / metal matrix composites, medium entropy alloys / metal matrix composites, multi-component alloys / metal matrix composites). In an example, the honeycomb core 130 is formed of a titanium alloy. The honeycomb core 130 may be optimized and tuned to have various thicknesses.

[0056] The honeycomb core 130 may be fabricated using a variety of additive manufacturing techniques including: fusion processes such as powder bed fusion or directed energy deposition; sintering processes such as binder jetting, material extrusion, and material jetting; and solid-state processes such as additive friction stir processing, ultrasonic additive processing, cold spraying, and the like.

[0057] The honeycomb core 130 may have various architectures. In an example, the honeycomb core 130 may have an open honeycomb architecture. In another example, the honeycomb core 130 may have a closed honeycomb architecture. In another example, the honeycomb core 130 may have a honeycomb architecture. The architecture of the honeycomb core 130 may be tuned and optimized to meet application requirements.

[0058] The honeycomb core 130 may be bonded to the first liner sheet 110 and the second liner sheet 120 by various methods, such as by welding, brazing, fastening, diffusion bonding (with or without interlayer foils / coatings), or additive manufacturing.

[0059] In an example, the honeycomb core 130 includes one or more third liner sheets. In another example, the honeycomb core 130 includes one or more third liner sheets 132 that are superplastic 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 technology for forming a hollow honeycomb sandwich panel of a complex shape. It combines superplastic forming with diffusion bonding to form a honeycomb sandwich panel. Typically, three or more liner sheets are welded together at their edges and then heated within the boundaries of a female mold. At high temperatures, the three or more liner sheets become extremely ductile, i.e., superplastic. When in a superplastic state, an inert gas is injected between the three or more liner sheets to form the three or more liner sheets into the shape of the female mold. Superplastic forming and diffusion bonding can be used for complex shapes. Therefore, the architecture of one or more third liner sheets 132 of the honeycomb core 130 can be tuned and optimized to meet a variety of application requirements. In the illustrated example, the honeycomb core 130 includes a double core structure having two third liner sheets 132 .

[0060] The honeycomb sandwich panel 100 can provide a thermal protection gradient function. In an example, the melting point or thermal microstructure stabilization point of the first lining sheet 110 is greater than the melting point or thermal microstructure stabilization point of the second lining sheet 120. In another example, the melting point or thermal microstructure stabilization point of the first lining sheet 110 is greater than the melting point or thermal microstructure stabilization point of the honeycomb core 130. In yet another example, the melting point or thermal microstructure stabilization point of the honeycomb core 130 is greater than the melting point or thermal microstructure stabilization point of the second lining sheet 120. In yet another example, the melting point or thermal microstructure stabilization point of the first lining sheet 110 is greater than the melting point or thermal microstructure stabilization point of the honeycomb core 130, and the melting point or thermal microstructure stabilization point of the honeycomb core 130 is greater than the melting point or thermal microstructure stabilization point of the second lining sheet 120. By providing the above-mentioned thermal protection gradient function, the honeycomb sandwich panel 100 has a hot side with higher resistance to high temperatures and a cold side with lower resistance to high temperatures.

[0061] In addition, by relaxing the requirement for high high temperature resistance of the cold side, the cold side can be made of a material that is lower in cost or has superior properties such as increased strength, increased damage tolerance, increased resistance to environmental cracking, increased formability, increased bondability, or increased producibility compared to the material of the hot side. Thus, by way of example, the strength, damage tolerance, resistance to environmental cracking, formability, bondability, or producibility of the second liner sheet 120 is greater than the strength, damage tolerance, resistance to environmental cracking, formability, bondability, or producibility of the first liner sheet 110. In another example, the strength, damage tolerance, resistance to environmental cracking, formability, bondability, or producibility of the second liner sheet 120 is greater than the strength, damage tolerance, resistance to environmental cracking, formability, bondability, or producibility of the honeycomb core 130. In yet another example, the strength, damage tolerance, resistance to environmental cracking, formability, bondability, or producibility of the honeycomb core 130 is greater than the strength, damage tolerance, resistance to environmental cracking, formability, bondability, or producibility of the first liner sheet 110. In yet another example, the strength, damage tolerance, resistance to environmental cracking, formability, bondability, or producibility of the second liner sheet 120 is greater than the strength, damage tolerance, resistance to environmental cracking, formability, bondability, or producibility of the honeycomb core 130, and the strength, damage tolerance, resistance to environmental cracking, formability, bondability, or producibility of the honeycomb core 130 is greater than the strength, damage tolerance, resistance to environmental cracking, formability, bondability, or producibility of the first liner sheet 110. By providing the above-mentioned thermal protection gradient function, the honeycomb sandwich panel 100 can have a hot side with higher resistance to high temperature but lower strength, damage tolerance, resistance to environmental cracking, formability, joinability or producibility, and a cold side with lower resistance to high temperature but higher strength, damage tolerance, resistance to environmental cracking, formability, joinability or producibility.

[0062] The first liner sheet 110 may include a first liner layer 112 proximate to the honeycomb core 130 and a second liner layer 114 proximate to the multilayer composite 200. The first liner layer 112 and the second liner layer 114 may provide a thermal protection gradient function. In an example, the melting point or thermal microstructural stabilization point of the second liner layer 114 is greater than the melting point or thermal microstructural stabilization point of the first liner layer 112. The first liner sheet 110 may also include a third or additional liner layer between the first liner layer 112 and the second liner layer 114, wherein the third or additional liner layer has a melting point or thermal microstructural stabilization point between the first liner layer 112 and the second liner layer 114. By providing the above-mentioned thermal protection gradient function of the first liner sheet 110, the first liner sheet 110 has a hot side with higher resistance to high temperatures and a cold side with lower resistance to high temperatures.

[0063] The first liner sheet 110 may provide compatibility with the multi-layer composite 200. In one aspect, the first liner layer 112 is compatible with the second liner layer 114, the second liner layer 114 is compatible with the multi-layer composite 200, but the first liner layer 112 is not compatible or not very compatible with the multi-layer composite 200. The first liner sheet 110 may also include a third liner layer or other liner layer between the first liner layer 112 and the second liner layer 114, wherein the third liner layer or other 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 not compatible or not very compatible with each other.

[0064] In an example, the composition of the first backing layer 112 includes an element that is detrimental to the properties of the multilayer composite 200, or the composition of the multilayer composite 200 includes an element that is detrimental to the properties of the first backing layer 112, and the second backing layer 114 does not include the detrimental element. Therefore, the first backing sheet 110 can provide improved compatibility of the honeycomb sandwich panel 110 with the multilayer composite 200.

[0065] In another example, the temperature for processing the multi-layer composite 200 exceeds the melting point or thermal microstructural stabilization point of the first liner layer 112, thereby rendering the first liner layer 112 and the multi-layer composite 200 incompatible, and the melting point or thermal microstructural stabilization point of the second liner layer 114 exceeds the temperature for processing the multi-layer composite 200, thereby rendering the second liner layer 114 and the multi-layer composite 200 more compatible. The temperature for processing the multi-layer composite 200 may include, for example, a bonding temperature, a sintering temperature, or a heat treatment temperature. Therefore, the first liner sheet 110 may provide improved compatibility of the honeycomb sandwich panel 110 with the multi-layer composite 200.

[0066] In yet another example, the thermal expansion coefficient of the first lining layer 112 differs greatly from the thermal expansion coefficient of the multilayer composite 200, while the thermal expansion coefficient of the second lining layer 114 differs less from the thermal expansion coefficient of the multilayer composite 200. Therefore, the first lining sheet 110 can provide improved compatibility of the honeycomb sandwich panel 110 with the multilayer composite 200.

[0067] In addition, the first lining layer 112 may be made of a material that is relatively low in cost or has superior properties such as increased strength, increased damage tolerance, increased resistance to environmental cracking, increased formability, increased bondability, or increased producibility. Thus, by way of example, the strength, damage tolerance, resistance to environmental cracking, formability, bondability, or producibility of the first lining layer 112 is greater than the strength, damage tolerance, resistance to environmental cracking, formability, bondability, or producibility of the second lining layer 114. Thus, by providing the above-mentioned compatibility of the honeycomb sandwich panel 100 with the multilayer composite 200, the honeycomb sandwich panel 100 may be provided with higher overall strength, damage tolerance, resistance to environmental cracking, formability, bondability, or producibility while maintaining compatibility with the multilayer composite 200.

[0068] As previously mentioned, the multi-layer composite 200 includes hollow microspheres 210 dispersed within a metal matrix material 220. The hollow microspheres 210 can provide lightweight characteristics as well as insulating, conductive, and / or noise / shock attenuating properties to the multi-layer composite 200. The metal matrix material 220 can provide durability and damage resistance to the multi-layer composite 200.

[0069] The metal matrix material 220 may be formed of various materials. In an example, the metal matrix material 220 is formed of at least one of an alloy material and a ceramic material, and the alloy material includes, but is not limited to, aluminum and aluminum alloys / metal matrix composites; titanium and titanium alloys / metal matrix composites; super alloys (including iron and iron alloys / metal matrix composites, nickel and nickel alloys / metal matrix composites, cobalt and cobalt alloys / metal matrix composites); refractory metals and alloys / metal matrix composites; copper and copper alloys / metal matrix composites; precious metals and alloys / metal matrix composites; zirconium and hafnium and their alloys / metal matrix composites; intermetallic substances; complex condensed alloys / metal matrix composites (high entropy alloys / metal matrix composites, medium entropy alloys / metal matrix composites, multi-component alloys / metal matrix composites). By forming the metal matrix material 220 from at least one of an alloy material and a ceramic material, high temperature resistance can be provided to the metal matrix material 220. In a specific example, the metal matrix material 220 is formed of a nickel-based super alloy. In another specific example, the metal matrix material is formed of a titanium-based super alloy.

[0070] The hollow microsphere 210 can be formed of various materials. In an example, the hollow microsphere 210 is formed of a ceramic material. By forming the hollow microsphere 210 from a ceramic material, the hollow microsphere 210 can be provided with high temperature resistance and deformation resistance to maintain its shape around the hollow interior. In a specific example, the ceramic material is formed of yttrium-stabilized zirconium oxide or alumina-silicon-iron glass. The architecture of the hollow microsphere 210 can be tuned and optimized so that the multilayer composite 200 can meet the application requirements. The architecture includes materials, coating size, cover thickness, coating thickness and type / material. In some implementations, the material of the hollow microsphere 210 is ceramic-based or metal-based, and the size range is between 5 microns and 500 microns in diameter and the average wall thickness is between 2% and 30% of the diameter. In some implementations, the hollow microsphere 210 is coated with a coating made of a metal, ceramic or mixed metal-ceramic material combination and having a coating thickness between 2 microns and 200 microns. The microsphere can also be solid. These example implementations provide for a multi-layer composite 200 that is tuned for a particular application.

[0071] In an example, the hollow microspheres 210 are included in the metal matrix material 220 at a volume fraction ranging between about 1% and 60%. The volume fraction of the hollow microspheres 210 is defined as the volume of all hollow microspheres 210 within the metal matrix material 220 divided by the total volume of the hollow microspheres 210 and the metal matrix material 220. A higher volume fraction of the hollow microspheres 210 increases the lightweight characteristics and the insulating, conductive and / or noise / impact attenuating properties of the multilayer composite 200. A lower volume fraction of the hollow microspheres 210 increases the durability and damage resistance of the multilayer composite 200.

[0072] In the example, the multilayer composite 200 includes a first layer 202 adjacent to the first liner sheet 110 and a second layer 204 adjacent to the first layer 202. The first layer 202 has a first matrix 222 including first hollow microspheres 212, and the second layer 204 has a second matrix 224 including second hollow microspheres 214.

[0073] The first layer 202 and the second layer 204 may provide a thermal protection gradient function. In an example, the melting point or thermal microstructural stability point of the second matrix 224 is greater than the melting point or thermal microstructural stability point of the first matrix 222. The multilayer composite 200 may also include a third layer or other layer between the first layer 202 and the second layer 204, wherein the third layer or other layer has a matrix having a melting point or thermal microstructural stability point between the melting point or thermal microstructural stability point of the first matrix 222 and the second matrix 224. By providing the above-mentioned thermal protection gradient function of the multilayer composite 200, the multilayer composite 200 has a hot side with higher resistance to high temperatures and a cold side with lower resistance to high temperatures.

[0074] The multilayer composite 200 may provide compatibility with the honeycomb sandwich panel 100. In an example, the first matrix 222 is compatible with the second backing layer 114 of the honeycomb sandwich panel 100, but the second matrix 224 is not compatible or not very compatible with the second backing layer 114 of the honeycomb sandwich panel 100. The multilayer composite 200 may also include a third layer or other layers between the first layer 202 and the second layer 204, wherein the third or other layers are compatible with the first layer 202 and the second layer 204, but the first layer 202 and the second layer 204 are not compatible or not very compatible with each other.

[0075] In an example, the composition of the second matrix 224 includes an element that is detrimental to the properties of the second backing layer 114, or the composition of the second backing layer 114 includes an element that is detrimental to the properties of the second matrix 224, and the second matrix 224 does not include the detrimental element. Therefore, the multilayer composite 200 can provide improved compatibility with the honeycomb sandwich panel 100.

[0076] In another example, the temperature for processing the second substrate 224 exceeds the melting point or thermal microstructural stabilization point of the second backing layer 114, thereby rendering the second substrate 224 incompatible with the second backing layer 114, and the melting point or thermal microstructural stabilization point of the second backing layer 114 exceeds the temperature for processing the first substrate 222, thereby rendering the first substrate 222 and the second backing layer 114 more compatible. The temperature for processing the first substrate 222 and the second substrate 224 may include, for example, a bonding temperature, a sintering temperature, or a heat treatment temperature. Therefore, the multilayer composite 200 may provide improved compatibility with the honeycomb sandwich panel 100.

[0077] In yet another example, the thermal expansion coefficient of the second layer 204 differs greatly from the thermal expansion coefficient of the second lining layer 114, while the thermal expansion coefficient of the first layer 202 differs less from the thermal expansion coefficient of the second lining layer 114. Therefore, the multilayer composite 200 may provide improved compatibility with the honeycomb sandwich panel 100.

[0078] In addition, the second matrix 224 can be formed of a material with lower cost or superior performance such as higher high temperature resistance. Therefore, by way of example, the melting point or thermal microstructure stability point of the second matrix 224 is greater than the melting point or thermal microstructure stability point of the first matrix 222. Therefore, by providing the above-mentioned compatibility of the multi-layer composite 200 with the honeycomb sandwich panel 100, the multi-layer composite 200 can be provided with higher high temperature resistance while maintaining compatibility with the honeycomb sandwich panel 100.

[0079] like Fig. 9 and Fig.10 As shown in FIG. 1 , the first layer 202 and the second layer 204 provide a spatial distribution of hollow microspheres 210. Fig. 9 and Fig.10The first layer 202 and the second layer 204 are shown to provide a gradient spatial distribution of hollow microspheres 210, but it is contemplated that the first layer 202 and the second layer 204 provide a substantially uniform (i.e., non-graded) spatial distribution of hollow microspheres 210. For purposes of illustration, only the gradient spatial distribution of hollow microspheres 210 will be described herein.

[0080] like Fig. 9 and Fig.10 , the volume fraction of the second hollow microspheres 214 in the second layer 204 is higher than the volume fraction of the first hollow microspheres 212 in the first layer 202. By way of example, the volume fraction of the second hollow microspheres 214 in the second layer 204 is at least 5% greater than the volume fraction of the first hollow microspheres 212 in the first layer 202, preferably at least 10% greater, more preferably at least 20% greater, even more preferably at least 50% greater, and even more preferably at least 100% greater. Therefore, the first layer 202 can have higher durability and damage resistance, while the second layer 204 can have a lower overall density and higher insulation, conductivity and / or noise / impact attenuation properties. In addition, compared to the second layer 202 in which the volume fraction of the second hollow microspheres 214 is higher, the first layer 202 in which the volume fraction of the first hollow microspheres 212 is lower is more compatible with the second liner layer 114. By way of specific example, the volume fraction of the first hollow microspheres 212 in the first layer 202 is about 10%, and the volume fraction of the second hollow microspheres 214 in the second layer 204 is about 45%. The first liner sheet 110 may also include a third or additional liner layer intermediate the first liner layer 112 and the second liner layer 114, wherein the third or additional liner layer has a melting point or thermal microstructural stability point intermediate the first liner layer 112 and the second liner layer 114. The multilayer composite 200 may also include a third or additional layer intermediate the first layer 202 and the second layer 204, wherein the third or additional layer has third or additional hollow microspheres having a different volume fraction of hollow microspheres.

[0081] although Fig. 9 and Fig.10 The first layer 202 and the second layer 204 are shown as generally planar layers in which the first layer 202 covers a surface of the honeycomb sandwich panel 100 and the second layer 204 covers a surface of the first layer 202, but other arrangements of the first layer 202 and the second layer 204 are included in the present description. For example, the first layer 202 and the second layer 204 each cover adjacent portions of the honeycomb sandwich panel 100. Therefore, the first layer 202 is more compatible for fastening with the second backing layer 114 of the honeycomb sandwich panel 100 than the second layer 204. Therefore, the first layer 202 can be disposed on the second backing layer 114, wherein the fastener connects the second backing layer 114 with the multilayer composite 200.

[0082] In another example, the composition of the second hollow microspheres 214 in the second layer 204 is different from the composition of the first hollow microspheres 212 in the first layer 202. For example, the composition of the second hollow microspheres 214 is selected to provide higher insulation, conductivity, and / or noise / shock attenuation properties than the insulation, conductivity, and / or noise / shock attenuation properties of the composition of the first hollow microspheres 212. Thus, the first layer 202 may have different properties such as insulation, conductivity, and / or noise / shock attenuation properties than the second layer 204.

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

[0084] Refer back Figures 7 to 10 The multilayer material system 10 further includes a barrier coating 300 on the surface of the multilayer composite 200 to prevent exposure to the environment and increase emissivity. The barrier coating 300 can have a variety of structures, compositions, and thicknesses.

[0085] The honeycomb sandwich panel 100 and the multilayer composite 200 are joined together to form the joint 400 by various methods, exemplary methods including welding, brazing, diffusion bonding, and fastening. In a specific example, the honeycomb sandwich panel 100 and the multilayer composite 200 are joined together to form the joint 400 using a compositionally graded brazed joint. In an example, the compositionally graded brazed joint includes a first braze layer adjacent to the honeycomb sandwich panel 100 and a second braze layer adjacent to the multilayer composite 200, wherein the thermal expansion coefficient of the first braze layer is compatible with the honeycomb sandwich panel 100 and the thermal expansion coefficient of the second braze layer is compatible with the multilayer composite 200. In addition, the compositionally graded brazed joint may include a third braze layer or an additional braze layer, the third braze layer or the additional braze layer being intermediate the first braze layer and the second braze layer, and having a thermal expansion coefficient intermediate the thermal expansion coefficients of the first braze layer and the second braze layer. Therefore, the compositionally graded brazed joint can accommodate the thermal expansion coefficient mismatch between the honeycomb sandwich panel 100 and the multilayer composite 200.

[0086] Although the multilayer material system 10 is illustrated as a planar configuration, the overall shape of the multilayer material system 10 may vary. For example, a curved surface or a compound curved surface of an area skin structure, an engine air inlet structure, a leading edge structure, a control surface structure, a thermomechanical isolator structure, or an integrated thermal protection system for an internal cold component may be formed from the multilayer material system 10.

[0087] Fig.11 It means used for manufacturing Figure 66 is a flow chart of a method 600 for forming a multilayer composite 200. The method 600 includes providing a first layer of a first powder having first hollow microspheres 212 dispersed therein in block 610, and providing a second layer of a second powder adjacent to the first layer of the first powder having second hollow microspheres 214 dispersed therein in block 620. The method 600 also includes heating the first layer of the first powder and the second layer of the second powder in block 630. The heating may occur at various levels of sustained stress and for various times.

[0088] In an example, the melting point or thermal microstructural stabilization point of the second layer of the second powder is greater than the melting point or thermal microstructural stabilization point of the first layer of the first powder. Thus, a thermal protective gradient function as previously described above may be provided to the multilayer composite 200.

[0089] In another example, the volume fraction of hollow microspheres in the second layer of the second powder is higher than the volume fraction of hollow microspheres in the first layer of the first powder. Thus, the multilayer composite 200 can be provided with a gradient spatial distribution of hollow microspheres 210 dispersed in the metal matrix material 220, as previously described.

[0090] The first layer of the first powder in which the first hollow microspheres 212 are dispersed and the second layer of the second powder in which the second hollow microspheres 214 are dispersed may be provided in various ways. In an example, the first hollow microspheres 212 and the second hollow microspheres 214 are premixed into the respective first and second powders. In another example, the first powder is provided as a first layer in a mold, and then the first hollow microspheres 212 are placed in the first layer, and the second powder is provided as a second layer in the mold, and then the second hollow microspheres 212 are placed in the second layer.

[0091] The second layer of the second powder can be placed adjacent to the first layer of the first powder by various methods. In an example, the first layer of the first powder is provided to the mold and then pressed with or without heating. Then, the second layer of the second powder is provided to the first layer in the mold, then pressed and heated together with the first layer of the first powder. In another example, the first layer of the first powder is provided to the mold, and then an interlayer material such as an interlayer foil or an interlayer net is provided on the first layer. Then, the second layer of the second powder is provided to the interlayer material on the mold, and heated together with the first layer of the first powder and the interlayer material. In yet another example, an interlayer barrier is provided to the mold to separate the first compartment from the second compartment. The first layer of the first powder is provided to the first compartment and the second layer of the second powder is provided to the second compartment, and then the first layer and the second layer are heated together with the interlayer barrier. Therefore, in various configurations, the first layer of the first powder and the second layer of the second powder can be arranged adjacent to each other.

[0092] In an 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. The heating may include a consolidation process such as 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.

[0093] In one aspect, the first layer or the second layer is sintered, consolidated, or heat treated before providing the other of the first layer or the second layer. For example, the processing temperature, such as the sintering temperature, consolidation temperature, or heat treatment temperature, of the second layer of the second powder may be 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 processed before providing the first layer of the first powder, and then the first layer of the first powder may be subjected to processing, such as 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 may be provided with a thermal protection gradient function as previously described above.

[0094] Fig.12 It means used for manufacturing Figure 6 Flowchart of method 700 of multilayer material system 10 of the present invention. Method 700 includes: providing a first layer of a first powder in frame 710, wherein first hollow microspheres 212 are dispersed in the first layer of the first powder; providing a second layer of a second powder adjacent to the first layer of the first powder in frame 720, wherein second hollow microspheres 214 are dispersed in the second layer of the second powder; and sintering the first layer of the first powder and the second layer of the second powder in frame 730. Method 700 also includes: providing at least one of a liner sheet and a honeycomb core in frame 740; and bonding the sintered first layer of the first powder to the at least one of the liner sheet and the honeycomb core in frame 750. In some implementations, the first layer of the first powder and the second layer of the second powder are sintered at a necessary stress for a necessary length of time.

[0095] In an example, the melting point or thermal microstructural stabilization point of the second layer of the second powder is greater than the melting point or thermal microstructural stabilization point of the first layer of the first powder. Thus, a thermal protective gradient function as previously described above may be provided to the multilayer composite 200.

[0096] In another example, the volume fraction of hollow microspheres in the second layer of the second powder is higher than the volume fraction of hollow microspheres in the first layer of the first powder. Thus, the multilayer composite 200 can be provided with a gradient spatial distribution of hollow microspheres 210 dispersed in the metal matrix material 220, as previously described.

[0097] The first layer of the first powder in which the first hollow microspheres 212 are dispersed and the second layer of the second powder in which the second hollow microspheres 214 are dispersed may be provided in various ways. In an example, the first hollow microspheres 212 and the second hollow microspheres 214 are premixed into the respective first and second powders. In another example, the first powder is provided as a first layer in a mold, and then the first hollow microspheres 212 are placed in the first layer, and the second powder is provided as a second layer in the mold, and then the second hollow microspheres 212 are placed in the second layer.

[0098] The second layer of the second powder can be placed adjacent to the first layer of the first powder by various methods. In an example, the first layer of the first powder is provided to the mold and then pressed with or without heating. Then, the second layer of the second powder is provided to the first layer in the mold, then pressed and heated together with the first layer of the first powder. In another example, the first layer of the first powder is provided to the mold, and then an interlayer material such as an interlayer foil or an interlayer net is provided on the first layer. Then, the second layer of the second powder is provided to the interlayer material on the mold, and heated together with the first layer of the first powder and the interlayer material. In yet another example, an interlayer barrier is provided to the mold to separate the first compartment from the second compartment. The first layer of the first powder is provided to the first compartment and the second layer of the second powder is provided to the second compartment, and then the first layer and the second layer are heated together with the interlayer barrier. Therefore, in various configurations, the first layer of the first powder and the second layer of the second powder can be arranged adjacent to each other.

[0099] In an example, sintering the first layer of the first powder and the second layer of the second powder includes a consolidation process such as hot isostatic pressing, spark plasma sintering, or cold isostatic pressing and sintering.

[0100] In one aspect, the first layer or the second layer is sintered before providing the other of the first layer or the second layer. For example, the sintering temperature of the second layer of the second powder can be higher than the melting point or thermal microstructural stability point of the first layer of the first powder. Therefore, the second layer of the second powder can be sintered before providing the first layer of the first powder, and then the first layer of the first powder can be subjected to sintering. Therefore, 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 a thermal protection gradient function as previously described above.

[0101] The honeycomb sandwich panel 100 can take various forms as previously described and can be formed according to various methods. In an example, the step of providing at least one of a liner sheet and a honeycomb core includes the step of providing a first liner sheet 110 in frame 742 and the step of providing a second liner sheet 120 in frame 744. The step of providing at least one of a liner sheet and a honeycomb core also includes providing one or more third liner sheets 132 between the first liner sheet 110 and the second liner sheet 120 in frame 746 and superplastic forming and diffusion bonding the one or more third liner sheets to the first liner sheet and the second liner sheet in frame 748.

[0102] The step of joining the first layer of the sintered first powder to at least one of the liner sheet and the honeycomb core can be performed by a variety of methods. Exemplary methods include welding, brazing, diffusion bonding, and fastening. In a specific example, at least one of the liner sheet and the honeycomb core is joined together with the multilayer composite 200 using a composition-graded brazed joint to form a joint 400. In an example, the step of joining the first layer of the sintered first powder to at least one of the liner sheet and the honeycomb core includes providing a first braze layer adjacent to at least one of the liner sheet and the honeycomb core and a second braze layer adjacent to the multilayer composite 200. The first braze layer may have a thermal expansion coefficient compatible with the honeycomb sandwich panel 100, and the second braze layer may have a thermal expansion coefficient compatible with the multilayer composite 200. In addition, the composition-graded brazed joint may include a third braze layer or an additional braze layer, the third braze layer or the additional braze layer being intermediate the first braze layer and the second braze layer, and having a thermal expansion coefficient intermediate the thermal expansion coefficients of the first braze layer and the second braze layer. Thus, the compositionally graded brazed joint may accommodate a mismatch in coefficient of thermal expansion between at least one of the liner sheet and the honeycomb core and the multilayer composite 200 .

[0103] The following illustrative, non-exclusive examples of subject matter covered herein are also provided, relating to:

[0104] A graded multilayer composite 1100 includes: a metal matrix material 1110 having a first side 1112 and a second side 1114 opposite to the first side 1112; a first microsphere layer 1120 dispersed on the first side 1112 of the metal matrix material 1110; and a second microsphere layer 1122 dispersed on the second side 1114 of the metal matrix material 1110.

[0105] In the graded multi-layer composite 1100 described in the immediately preceding paragraph, the density of a first portion of the graded multi-layer composite was different than the density of a second portion of the graded multi-layer composite.

[0106] In the graded multi-layer composite 1100 described in either of the two immediately preceding paragraphs, the metal matrix material 1110 comprises a compositionally graded material.

[0107] In the graded, multi-layer composite 1100 described in the immediately preceding paragraph, the composition of the metal matrix material 1110 includes at least one of aluminum, aluminum alloys / metal matrix composites, titanium, titanium alloys / metal matrix composites, iron, iron alloys / metal matrix composites, nickel, nickel alloys / metal matrix composites, cobalt, cobalt alloys / metal matrix composites, refractory metals, refractory metal alloys / metal matrix composites, copper, copper alloys / metal matrix composites, precious metals, precious metal alloys / metal matrix composites, zirconium, zirconium alloys / metal matrix composites, hafnium, hafnium alloys / metal matrix composites, and intermetallic substances.

[0108] In the graded, multi-layer composite 1100 described in any of the immediately preceding four paragraphs, wherein (i) the microspheres in the first microsphere layer 1120 are spatially distributed relative to each other based on a first spatial gradient, and (ii) the microspheres in the second microsphere layer 1122 are spatially distributed relative to each other based on a second spatial gradient, the second spatial gradient being different from the first spatial gradient.

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

[0110] In the graded, multilayer composite 1100 described in either of the two immediately preceding paragraphs, the first spatial gradient and the second spatial gradient are based on the number of microspheres.

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

[0112] In the graded multi-layer composite 1100 described in any of the immediately preceding eight paragraphs, wherein (i) the density of the first portion of the graded multi-layer composite is different than the density of the second portion of the graded multi-layer composite, (ii) the metal matrix material 1110 comprises a compositionally graded material, (iii) the microspheres in the first microsphere layer 1120 are spatially distributed relative to each other based on a first spatial gradient, and (iv) the microspheres in the second microsphere layer 1122 are spatially distributed relative to each other based on a second spatial gradient, the second spatial gradient being different from the first spatial gradient.

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

[0114] A multilayer material system 1200 comprising: a graded multilayer composite 1100 as described in any of the ten preceding paragraphs; and a layer 1150 joined to the graded multilayer composite 1100 and selected from a monolithic or graded metal liner, a monolithic or graded ceramic liner, or 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.

[0115] In the multilayer material system 1200 described in the immediately preceding paragraph, layer 1150 includes at least one graded layer.

[0116] A method of making the multilayer material system 1200 described in either of the two immediately preceding paragraphs includes joining the layer 1150 to the graded multilayer composite 1100 to provide the multilayer material system 1200 .

[0117] In the method described in any of the preceding paragraphs, 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.

[0118] A multilayer material system 1250 includes: a non-graded multilayer composite 1260; and at least one layer 1280, which is joined to the graded multilayer composite 1260 and is selected from a monolithic or graded metal liner, a monolithic or graded ceramic liner, or 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.

[0119] In the multilayer material system 1250 described in the immediately preceding paragraph, the non-hierarchical multilayer composite 1260 includes a non-hierarchical microsphere layer 1264 .

[0120] In the multilayer material system 1250 described in either of the two immediately preceding paragraphs, the non-graded multilayer composite 1260 includes a substantially uniform composition of a metal matrix material 1262 within the multilayer composite.

[0121] In the multilayer material system 1250 described in any of the three immediately preceding paragraphs, the non-hierarchical multilayer composite 1260 includes a metal matrix material 1262 having a non-hierarchical microsphere layer 1264 dispersed therein.

[0122] A method of manufacturing a multi-layer material system, the method comprising the steps of providing a non-graded multi-layer composite; and joining at least one graded layer to the non-graded multi-layer composite to provide the multi-layer material system.

[0123] In the method described in any of the preceding paragraphs, 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.

[0124] The above description describes a wide range of materials. It should be understood that "metal / metallic" includes "metals and metal matrix composites"; "ceramics" includes "ceramics and ceramic matrix composites"; and "mixed metal-ceramics" includes "metal-ceramic mixtures and metal matrix composites / ceramic matrix composite mixtures". In addition, metal matrices include aluminum and aluminum alloys / metal matrix composites; titanium and titanium alloys / metal matrix composites; superalloys (including iron and iron alloys / metal matrix composites, nickel and nickel alloys / metal matrix composites, cobalt and cobalt alloys / metal matrix composites); refractory metals and alloys / metal matrix composites; copper and copper alloys / metal matrix composites; precious metals and alloys / metal matrix composites; zirconium and hafnium and their alloys / metal matrix composites; intermetallics; complex concentrated alloys / metal matrix composites (high entropy alloys / metal matrix composites, medium entropy alloys / metal matrix composites, multi-component alloys / metal matrix composites).

[0125] It should be clear that the Figure 1 The graded multilayer composite 1100, Figure 2A and Figure 2B Hierarchical multi-layer material system 1200, FIG. 3A to FIG. 3E The multilayer material system 1300a-1300g and Figures 7 to 10 Each of the multilayer material systems 10 comprises a tuned multilayer composite or multilayer material system operable under severe thermomechanical load requirements, such as on an aircraft.

[0126] Available in Fig.13 Aircraft manufacturing and service method 1000 as shown in Fig.14 Examples of the present disclosure are described in the context of an aircraft 1002 as shown. During pre-production, aircraft manufacturing and service method 1000 may include specification and design 1004 of aircraft 1002 and material procurement 1006. During production, component / subassembly manufacturing 1008 and system integration 1010 of aircraft 1002 occurs. Thereafter, aircraft 1002 may be certified and delivered 1012 for placement in service 1014. While in service with a customer, aircraft 1002 may be scheduled for a routine maintenance overhaul 1016, which may also include modification, reconfiguration, refurbishment, and the like.

[0127] Each of the processes of method 1000 may be performed or executed 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, but is not limited to, any number of aircraft manufacturers and main system subcontractors; a third party may include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0128] The method may be employed during any one or more of the stages of aircraft manufacturing and service method 1000. Figure 1 The graded multilayer composite 1100, Figure 2A and Figure 2B Hierarchical multi-layer material system 1200, FIG. 3A to FIG. 3E The multilayer material system 1300a-1300g and Figures 7 to 10 The stages include specification and design 1004 of an 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 overhaul 1016.

[0129] like Fig.14As shown in FIG. 1 , an aircraft 1002 produced by method 1000 may include a fuselage 1018 having a plurality of high-level systems 1020 and an interior 1022. Examples of plurality of systems 1020 may include one or more of propulsion system 1024, electrical system 1026, hydraulic system 1028, and environmental system 1030. Any number of other systems may be included. The multilayer material system 10 of the present disclosure may be used in any of the systems of aircraft 1002.

[0130] Although various examples of the disclosed multilayer material system and multilayer composition have been shown and described, modifications may occur to one skilled in the art upon reading the specification. The present application includes all such modifications and is limited only by the scope of the claims.

Claims

1. A graded multi-layer composite (1100), comprising: a sintered metal matrix material having a first edge on a first side (1112) of the sintered metal matrix material and a second edge on a second side (1114) of the sintered metal matrix material opposite the first side (1112), the sintered metal matrix material having a sintered metal matrix from the first edge to the second edge throughout the sintered metal matrix material; a first layer of hollow microspheres (1120) dispersed on the first side (1112) of the sintered metal matrix material; a second layer of hollow microspheres (1122) dispersed on the second side (1114) of the sintered metal matrix material; as well as one or more cooling channels located in the sintered metal matrix material between the first edge and the second edge, wherein (i) the hollow microspheres in the first hollow microsphere layer (1120) are spatially distributed relative to each other based on a first spatial gradient, and (ii) the hollow microspheres in the second hollow microsphere layer (1122) are spatially distributed relative to each other based on a second spatial gradient, the second spatial gradient being different from the first spatial gradient, The first spatial gradient and the second spatial gradient are based on the number of hollow microspheres or the size of hollow microspheres.

2. The graded multilayer composite (1100) according to claim 1, wherein: The density of the first portion of the graded multi-layer composite is different than the density of the second portion of the graded multi-layer composite.

3. The graded multilayer composite (1100) according to claim 1 or 2, wherein: The sintered metal matrix material comprises a compositionally graded material.

4. The graded multilayer composite (1100) according to claim 3, wherein: The composition of the sintered metal matrix material includes 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 intermetallic substances.

5. The graded multi-layer composite (1100) of claim 1, further comprising: a first buffer region (1140) defined between the first hollow microsphere layer (1120) and the first edge (1113) of the first side (1112) of the sintered metal matrix material; as well as a second buffer region (1142) defined between the second hollow microsphere layer (1122) and the second edge (1115) of the second side (1114) of the sintered metal matrix material; Wherein, each of the first buffer region (1140) and the second buffer region (1142) has no hollow microspheres.

6. The graded multi-layer composite (1100) according to claim 3, further comprising: a first buffer region (1140) defined between the first hollow microsphere layer (1120) and the first edge (1113) of the first side (1112) of the sintered metal matrix material; as well as a second buffer region (1142) defined between the second hollow microsphere layer (1122) and the second edge (1115) of the second side (1114) of the sintered metal matrix material; Wherein, each of the first buffer region (1140) and the second buffer region (1142) has no hollow microspheres.

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