Monolithic Fragmentation Casing via Powder Bed Fusion
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Solution Overview
Problem
Conventional fragmentation casings face challenges with preformed fragments, such as assembly difficulties, lack of strength members, parasitic mass, uneven fragment distribution, and limited manufacturability, particularly with case scoring methods that restrict warhead shapes and fragment sizes.
Innovation Solution
A monolithic fragmentation casing is created using a hollow tubular structure with alternating rings of fused powder elements, where smaller connectors link larger elements, and a contiguous lattice, fabricated through powder bed fusion, allowing for a single-material, solid construction that retains explosive fill and provides enhanced structural integrity and localized blast effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If preformed fragments are used in conventional fragmentation casings, then fragment distribution and size control are improved, but assembly difficulty increases and strength members are lost
Solution Approach 1:
The patent merges the fragment elements and strength members into a single integrated lattice structure. The lattice framework provides both structural support and fragmentation functionality, eliminating the need for separate assembly of fragments and strength members. This unified approach maintains precise fragment distribution while significantly reducing assembly complexity.
Solution Approach 2:
The lattice structure is segmented into repeating unit cells that can be manufactured independently and then assembled. Each unit cell contains the fragment elements and structural components in a predefined configuration, allowing for modular manufacturing and simplified final assembly while maintaining overall fragment distribution precision.
2Reliability
If liners are used to retain preformed fragments, then fragment retention is improved, but parasitic mass increases and fragment velocity decreases
Solution Approach 1:
The retention function previously performed by separate liners is merged into the lattice structure itself. The lattice framework provides inherent retention through its geometric configuration and interlocking unit cells, eliminating the need for additional liner mass while maintaining reliable fragment retention during launch and impact.
3Ease of manufacture
If case scoring or notching is used to induce fragmentation, then fragment creation is simplified, but manufacturability is limited to small range of warhead shapes and fragment sizes
Solution Approach 1:
The lattice structure parameters (unit cell geometry, element dimensions, spacing) can be varied to produce different fragment sizes and shapes. By changing these geometric parameters, the same manufacturing process can produce fragments tailored to different warhead configurations and mission requirements, significantly expanding design versatility.
Solution Approach 2:
The lattice is composed of standardized unit cells that can be replicated and scaled. This modular approach allows the same manufacturing process to produce different overall warhead shapes and fragment sizes by varying the number and arrangement of unit cells, maintaining ease of manufacture while achieving versatility.
4Reliability
If preformed fragments are adhered to a liner, then fragment retention is improved, but strength members are lost and assembly complexity increases
Solution Approach 1:
The lattice structure combines fragment retention and structural strength functions into a single integrated framework. The lattice elements themselves provide both the retention mechanism for fragments and the structural strength required, eliminating the need for separate strength members and adhesive bonding processes.
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 monolithic casing design addresses assembly and strength issues, enabling uniform fragment distribution and size customization, reducing manufacturing defects and costs, while providing improved performance during detonation and potential incendiary effects.
Implementation Method 1
fabricated through powder bed fusion
Implementation Method 2
When the monolithic casing is filled with explosive material and the explosive material is detonated
Data Source
AI summary
A fragmentation casing includes a monolithic tube defined by an alternating axial arrangement of first and second rings. Each first ring is a contiguous ring of fused powder defining spaced-apart first elements of the fused powder and at least one second element of the fused powder joining adjacent ones of the first elements. Each second ring is a contiguous lattice of the fused powder. Each of the first elements is contiguous with a portion of the lattice associated with at least one of the second rings.