Multi-Layer Metallic Armor with Non-Bonded Crack-Arrest Regions
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Solution Overview
Problem
Forming high-strength multi-layered metallic parts, such as armor steel plates, into desired shapes is challenging due to their thickness and difficulty in controlling crack propagation from impacts, which existing methods fail to address effectively.
Innovation Solution
A method involving stacking metallic layers with diffusion-bond preventing elements between them to create non-bonded regions, which helps in controlling crack propagation by promoting fracture capture and energy dissipation, using thermally insulating materials like boron nitride and yttrium oxide to prevent diffusion bonding at specific locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength steel plates are made thick and strong to withstand powerful impacts, then the strength and impact resistance are improved, but the difficulty of forming them into desired shapes increases
Solution Approach 1:
The armor plate is divided into multiple layers of alternating high-strength and ductile materials. Each layer can be formed independently into desired shapes, and the layered structure provides both strength and formability. The high-strength layers provide impact resistance while the ductile layers enable easier forming operations.
Solution Approach 2:
The invention uses composite material structure with alternating layers of high-strength material and ductile material. This composite approach combines the advantages of both materials: the high-strength layers provide impact resistance while the ductile layers provide formability, resolving the contradiction between strength and ease of manufacture.
2Stability of the object's composition
If conventional diffusion bonding is used to bond all metallic layers together, then the structural integrity is improved, but the ability to control crack propagation is reduced
Solution Approach 1:
The bonding characteristics are made non-uniform across the interface. Some regions are diffusion-bonded to maintain structural integrity, while other regions are intentionally left unbonded to control crack propagation. This local variation in bonding quality allows simultaneous achievement of both structural integrity and crack propagation control.
Solution Approach 2:
A thermally insulating material is introduced as an intermediary layer between the metallic layers. This intermediary prevents diffusion bonding in specific regions by blocking heat transfer, thereby creating controlled non-bonded regions that facilitate crack propagation control while maintaining overall structural integrity through bonded regions.
3Reliability
If thermally insulating material is interposed between metallic layers, then crack propagation control is improved, but the diffusion bonding efficiency is reduced
Solution Approach 1:
The interface between metallic layers is segmented into bonded regions and non-bonded regions. The thermally insulating material is placed only in specific locations to prevent bonding where crack control is needed, while other regions remain bonded for structural integrity. This segmented approach minimizes the impact on overall bonding efficiency.
Solution Approach 2:
The thermally insulating material is applied locally rather than uniformly across the entire interface. This localized application ensures that diffusion bonding efficiency is maintained in regions where structural integrity is prioritized, while crack propagation control is achieved only in critical regions where the insulating material is present.
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 method effectively constrains crack propagation and absorbs impact energy by creating non-bonded regions within the multi-layered metallic parts, enhancing their ability to capture and dissipate fracture energy from projectile impacts.
Implementation Method 1
interposing a diffusion-bond preventing element directly between adjacent ones of the at least two metallic layers... The diffusion-bond preventing element comprises a thermally insulating material
Data Source
AI summary
Disclosed herein is a method of forming a multi-layered metallic part. The method comprises stacking at least two metallic layers, each made of a metallic material having a ductility, to form a multi-layered metallic assembly. The method also comprises interposing a diffusion-bond preventing element directly between adjacent ones of the at least two metallic layers of the multi-layered metallic assembly. The method further comprises diffusion bonding the at least two metallic layers to each other at locations other than a location contiguous with the diffusion-bond preventing element to produce a multi-layered metallic part having a non-bonded region between the at least two metallic layers at the location of the diffusion-bond preventing element.