Compositionally-Graded Metal-Ceramic Armor for Impact Protection

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Solution Overview

Problem

Current high-energy impact protection materials, such as ceramic-based armor, are heavy, costly, and offer limited multi-hit protection due to their density and manufacturability issues, making them unsuitable for applications where weight is a concern and repeated impacts are possible.

Innovation Solution

A compositionally-graded metal-ceramic structure with continuous transitions of ceramic and metallic components along the thickness axis, where the ceramic component concentration is at least 95% by volume at certain locations, is developed, along with an anti-spalling layer, using a manufacturing method involving powder layup and heat treatment to create a consolidated mass that transitions from primarily ceramic to primarily metallic, reducing material requirements and enhancing impact absorption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If ceramic materials are used for high-energy impact protection, then impact resistance is improved, but weight increases

Engineering Contradiction:

Improveimpact resistanceVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies local quality by creating a compositionally-graded structure where the ceramic component concentration varies continuously from 95% or more at the impact-facing surface to lower concentrations toward the rear surface. This gradient distribution allows the material to have high ceramic content where impact resistance is most needed while reducing ceramic content elsewhere to decrease overall weight, thereby resolving the contradiction between impact resistance and weight.

Inventive Principle:

Principle #3Local quality

2Strength

If ceramic materials are used for high-energy impact protection, then impact resistance is improved, but multi-hit protection capability deteriorates

Engineering Contradiction:

Improveimpact resistanceVSAvoidmulti-hit protection capability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The compositionally-graded structure with continuous transition of ceramic concentration provides local quality variations that prevent catastrophic failure. The gradient design ensures that when one region is impacted, the continuous compositional transition prevents shock wave reflection and material spallation, allowing the structure to maintain integrity and protect against subsequent impacts, thereby improving multi-hit protection capability while maintaining impact resistance.

Inventive Principle:

Principle #3Local quality

3Strength

If traditional ceramic armor is used, then impact protection is achieved, but manufacturability deteriorates

Engineering Contradiction:

Improveimpact protectionVSAvoidmanufacturability

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies parameter changes by transitioning from traditional discrete-layer ceramic armor to a compositionally-graded structure with continuous compositional variation. This fundamental parameter change in the material architecture enables new manufacturing approaches such as selective laser sintering and powder bed fusion, which can directly fabricate complex gradient structures in a single process, thereby dramatically improving manufacturability while maintaining impact protection capabilities.

Inventive Principle:

Principle #35Parameter changes

4Strength

If ceramic materials are used for high-energy impact protection, then protection effectiveness is improved, but cost increases

Engineering Contradiction:

Improveprotection effectivenessVSAvoidcost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The compositionally-graded structure represents a parameter change that enables more cost-effective manufacturing. By using additive manufacturing processes like selective laser sintering, the complex gradient structure can be fabricated directly from digital models without expensive tooling or assembly operations. This reduces manufacturing cost while maintaining protection effectiveness, as the gradient design optimizes material distribution to provide maximum protection with minimum material usage.

Inventive Principle:

Principle #35Parameter changes

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

The compositionally-graded structure provides improved impact energy absorption and multi-hit performance by slowing impact wave propagation, reducing material weight and cost, while maintaining effective high-energy impact protection.

Implementation Method 1

The compositionally-graded structure provides improved impact energy absorption and multi-hit performance by slowing impact wave propagation

Methodology Applied

Scientific EffectImpact energy absorption:

Implementation Method 2

heat treating the compact

Methodology Applied

Scientific EffectHeat treatment: Heat Treatment

Data Source

PatentUS11255641B2Compositionally-graded metal-ceramic structure and method for manufacturing the same

Publication Date: 2022.02.22 THE BOEING CO

AI summary

A compositionally-graded structure including a body having a first major surface and a second major surface opposed from the first major surface along a thickness axis, the body including a metallic component and a ceramic component, wherein a concentration of the ceramic component in the body is a function of location within the body along the thickness axis, wherein transitions of the concentration of the ceramic component in the body are continuous such that distinct interfaces are not macroscopically established within the body, and wherein the concentration of the ceramic component is at least 95 percent by volume at at least one location within the body along the thickness axis.