Laser Sintered Warhead Casing for Splinter Control
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Solution Overview
Problem
Conventional warhead casings made from aluminum or steel are prone to causing collateral damage due to splintering, and existing alternatives struggle to balance weight, strength, and complexity in design.
Innovation Solution
A warhead casing manufactured using selective laser sintering with a powder blend of metal particles and a binding component, such as aluminum and polyamide, allowing for complex geometries and reduced weight while being splinter-proof, with optional reinforcement and sealing for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional aluminum or steel casings are used, then strength is improved, but collateral damage occurs due to splinter
Solution Approach 1:
The patent applies porous materials by using a laser-sintered casing structure with controlled porosity. The laser sintering process creates a porous microstructure that absorbs impact energy and prevents splinter formation, thereby maintaining strength while eliminating the harmful splinter effect that causes collateral damage.
Solution Approach 2:
The patent applies composite materials by combining metal powder particles with a binding component to create a laser-sintered composite casing. This composite structure integrates the strength properties of metal particles with the binding agent, achieving both mechanical strength and splinter resistance through the composite nature of the material.
2Strength
If aluminum or steel casings are used, then strength is improved, but weight is increased
Solution Approach 1:
The porous structure created by laser sintering reduces the density and weight of the casing compared to solid aluminum or steel. The controlled porosity maintains structural integrity while significantly reducing mass, addressing the weight concern without sacrificing strength.
Solution Approach 2:
The patent applies parameter changes by altering the material density and structural parameters through the laser sintering process. By controlling sintering parameters such as laser power, scanning speed, and layer thickness, the casing achieves optimal strength-to-weight ratio with reduced density compared to conventional solid metal casings.
3Ease of manufacture
If simple warhead configurations are used, then manufacturing is simplified, but design complexity is limited
Solution Approach 1:
The patent replaces traditional mechanical manufacturing methods (machining, assembling multiple components) with laser sintering technology. This substitution enables direct fabrication of complex geometries from digital models, eliminating the need for complex tooling and assembly processes while achieving design flexibility that was previously impossible with conventional manufacturing.
Solution Approach 2:
The laser sintering process allows for parameter changes in design geometry without increasing manufacturing complexity. By adjusting digital design parameters and re-sintering, complex geometries can be produced directly, providing adaptability and versatility while maintaining manufacturing simplicity through a single-process approach.
4Weight of moving object
If laser sintering is used, then weight is reduced and design complexity is improved, but material density must be sufficiently low
Solution Approach 1:
The patent applies parameter changes by optimizing the laser sintering parameters (power, speed, hatching distance) and powder bed density to achieve the desired material density range. By carefully controlling these parameters, the process produces casings with sufficiently low density for weight reduction while maintaining adequate structural reliability and strength.
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 laser-sintered warhead casing achieves reduced weight and strength while preventing collateral damage, enabling more complex designs and improved handling of launch forces without the need for additional machining, and demonstrates durability through testing.
Implementation Method 1
A laser beam is moved layer by layer over a powder bed of fine particles in accordance with the model. The laser beam locally heats the powder to the melting point, without the temperature exceeding the melting point, and the powder grains are thereby sintered together.
Implementation Method 2
The laser beam locally heats the powder to the melting point, without the temperature exceeding the melting point, and the powder grains are thereby sintered together.
Data Source
Figure 1~3
AI summary
A casing for warhead components, and a warhead comprising such casing, wherein the casing is made up of a laser sintered material. The laser sintered material may comprise metal powder such as aluminium powder and binder particles. The casing may be provided with a lacquer coating, and optionally an outer lining. A warhead comprising a casing as defined in claims 1-8.