Additive Manufactured Armor with Integrated Ceramic Areas
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Solution Overview
Problem
Existing methods for producing composite armor materials struggle to create complex three-dimensional configurations, limiting their effectiveness in providing multi-hit resistance against projectiles.
Innovation Solution
The method involves using additive manufacturing to build a three-dimensional geometry with a denser metallic material and a less dense material that reacts with a reaction gas to form ceramic areas, allowing for the creation of complex ceramic structures within metallic armor, enhancing multi-hit resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ceramic material is used on the outside of armor to strengthen metallic armor, then hardness and projectile interception capability are improved, but multi-hit resistance deteriorates because ceramic can break through impact and flake off
Solution Approach 1:
The patent applies composite materials by combining metallic build-up material with ceramic-forming material in a layered structure. The metallic material provides toughness and multi-hit resistance, while the ceramic-forming material provides hardness for projectile interception. This composite structure resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The patent applies local quality by creating distinct layers with different properties: a first layer of metallic material with high toughness and a second layer of ceramic-forming material with high hardness. Each layer is positioned where its specific properties are most needed, with the ceramic layer facing the projectile for hardness and the metallic layer behind it for energy absorption and multi-hit resistance.
2Adaptability or versatility
If additive manufacturing is used to build three-dimensional armor geometry, then manufacturing flexibility and complex shape capability are improved, but manufacturing precision deteriorates due to compaction variability
Solution Approach 1:
The patent applies segmentation by dividing the build-up material into distinct layers: a first layer that is compacted to high density and a second layer that remains less compacted. This segmentation allows each layer to be manufactured with appropriate density for its function, resolving the precision issue while maintaining 3D manufacturing flexibility.
Solution Approach 2:
The patent applies local quality by applying different compaction levels to different regions of the armor structure. The first layer receives high compaction for structural integrity, while the second layer receives minimal compaction to maintain porosity for ceramic formation. This localized quality control resolves the contradiction between manufacturing flexibility and precision.
3Reliability
If ceramic material is embedded in metallic material to avoid spalling, then multi-hit resistance is improved, but manufacturing complexity increases due to infiltration process requirements
Solution Approach 1:
The patent applies preliminary action by pre-forming the metallic and ceramic-forming material layers in the desired configuration before any infiltration or reaction processes. The layers are deposited in sequence with the metallic material first, followed by the ceramic-forming material, establishing the correct structure before subsequent thermal processing occurs.
Solution Approach 2:
The patent applies parameter changes by utilizing temperature as a control parameter to transform the less compacted ceramic-forming material into ceramic through reaction with atmospheric gas. This temperature-driven phase change simplifies the manufacturing process by eliminating the need for complex infiltration equipment, while still achieving the desired embedded ceramic structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of metallic armor with integrated ceramic areas that can withstand multiple impacts, offering improved resistance and allowing for intricate three-dimensional designs.
Implementation Method 1
A building material is used which reacts with a reaction gas to form a ceramic material
Implementation Method 2
a first part of the construction material being compressed during the additive manufacturing process
Implementation Method 3
the building material is continuously deposited locally, melted by the moving heat source and then cooled again so that a solidified layer is formed
Data Source
Figure 1
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Figure 4~5
AI summary
The invention relates to a method for producing a composite material (10) for armor plating (12), wherein a three-dimensional final geometry (14) of the composite material (10) is built up from a build-up material (23) using an additive manufacturing process, wherein a first part (24) of the build-up material (23) is densified during the additive manufacturing process and wherein a second part (26) of the build-up material (23) remains in a phase with a lower density (44) than the first part (24), wherein a build-up material (23) is used which reacts with a reaction gas (54) to form a ceramic material (58).The invention further relates to a method for producing a metallic armor (12) with integrated ceramic areas (64), wherein several modules (66) are provided which are formed by the method according to the invention, wherein the modules (66) are joined to form an armor (12), and to a metallic armor (12) with integrated ceramic areas (64).