Calcium Boride Armor Composite Hardness Density

The patent employs composite materials by combining calcium boride compounds with silicon carbide and boron carbide in specific proportions. This composite approach allows the armor component to achieve both high hardness from the carbide phases and improved density from the calcium boride matrix, resolving the contradiction between hardness and density that limits traditional single-material armor systems.

The patent utilizes parameter changes by controlling the stoichiometry of calcium boride (using both stoichiometric CaB6 and non-stoichiometric CaBx where x<6) and optimizing the particle size distribution of all constituent materials. These parameter adjustments enable the composite to achieve optimal packing density and mechanical properties, simultaneously improving density without sacrificing hardness.

The multi-phase composite structure combining calcium boride, silicon carbide, and boron carbide creates a synergistic effect where the harder carbide phases provide penetration resistance while the calcium boride matrix contributes to toughness. This composite architecture resolves the contradiction between penetration resistance and toughness by distributing mechanical stresses across different phases with complementary properties.

The patent applies local quality by creating a heterogeneous microstructure where different phases are distributed throughout the material. The silicon carbide and boron carbide particles are dispersed within the calcium boride matrix, with each phase performing its specialized function: the carbide phases provide localized hard points for penetration resistance while the calcium boride provides a tougher matrix that prevents catastrophic failure.

The patent applies preliminary action by pre-mixing the calcium boride, silicon carbide, and boron carbide powders in the correct proportions before sintering. This pre-mixing step ensures homogeneous distribution of phases throughout the green body, simplifying the subsequent sintering process and reducing manufacturing complexity while maintaining the desired high density and multi-phase structure.

The patent utilizes parameter changes by optimizing the sintering temperature, pressure, and atmosphere to achieve dense consolidation of the multi-phase composite. By carefully controlling these sintering parameters, the process achieves high density without requiring excessively complex manufacturing steps, as the pre-mixed powder composition facilitates uniform densification throughout the component.