Monolithic Fragmentable Warhead Additive Manufacturing

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Solution Overview

Problem

Traditional preformed fragment warheads are heavy and parasitic, contributing little to structural stiffness and strength, and are susceptible to vibration and shock, with limited manufacturing capabilities for varied designs.

Innovation Solution

A fragmentable package is created by additively depositing layers of selected metals or composites to form interconnected fragments with voids, providing structural stiffness and strength, and minimizing parasitic mass through controlled layer deposition and voids.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional preformed fragment warheads are used, then fragments can be produced, but the mass is parasitic and does not contribute to structural stiffness and strength

Engineering Contradiction:

Improvestructural stiffness and strengthVSAvoidmass of fragments

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent merges the structural function and fragment function into a single integrated component. The monolithic warhead structure serves both as the structural housing and as the source of fragments upon detonation, eliminating the need for separate preformed fragment packages that would add parasitic mass.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The warhead structure is designed to perform multiple functions simultaneously: it provides structural stiffness and strength for delivery system compatibility, and it serves as the fragment source upon detonation. This multi-functionality eliminates the need for dedicated fragment packages that would increase mass without contributing to structural performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If preformed fragmentable packages are used, then fragments can be generated, but they are susceptible to vibration and shock environments

Engineering Contradiction:

Improveresistance to vibration and shockVSAvoidvibration and shock sensitivity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

By integrating the fragment package with the structural housing into a single monolithic component, the patent eliminates the interface between separate elements that would be susceptible to vibration and shock. The unified structure distributes mechanical loads more effectively and reduces sensitivity to harmful environmental factors during delivery.

Inventive Principle:

Principle #5Merging (Combining)

3Productivity

If traditional manufacturing methods are used, then fragmentable packages can be produced, but the process is labor and process intensive

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidlabor and process intensity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical assembly processes (hand packing, casting in binders) with additive manufacturing technology. This substitution eliminates labor-intensive operations and complex assembly procedures, enabling direct fabrication of the monolithic warhead structure with integrated fragment packages through computer-controlled layer deposition.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The manufacturing process transitions from subtractive or assembly-based methods to additive manufacturing, fundamentally changing how the warhead is produced. This parameter change in the manufacturing approach enables complex geometries to be created directly without requiring separate steps for forming fragments and assembling them into the final configuration.

Inventive Principle:

Principle #35Parameter changes

4Quantity of substance

If casting fragmentable packages in a binder is used, then fragments can be formed, but the density of individual fragments is reduced

Engineering Contradiction:

Improvedensity of fragmentsVSAvoidmanufacturing method

Core Design Contradiction:

Quantity of substanceVSEase of manufacture

Solution Approach 1:

The patent replaces the binder-casting manufacturing method with additive manufacturing using metal powders or composites. This substitution eliminates the need for binding agents that would reduce fragment density, enabling direct formation of high-density fragments through controlled layer deposition of metallic materials.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution results in a lightweight warhead with enhanced structural integrity and reduced sensitivity to shock and vibration, allowing for efficient use in delivery systems like missiles while maintaining effectiveness against targets.

Implementation Method 1

individual fragments formed by additively depositing layers, of at least one of selected metal type and a composite that includes a selected metal type

Methodology Applied

Scientific EffectAdditive deposition: Deposition (physical)

Data Source

PatentUS10018453B1Lightweight monolithic warhead and a method of manufacture

Publication Date: 2018.07.10 LOCKHEED MARTIN CORP

AI summary

A fragmentable package for use in an explosive armament, is disclosed having individual fragments formed by additively depositing layers, of at least one of selected metal type and a composite that includes a selected metal type, to create interconnected individual fragments to form a plurality of voids around an individual outer surface of the individual fragments defining a separation of fragments when detonated, the individual fragments providing structural stiffness and strength. A method is also disclosed.