Multi-Layer Metallic Armor With Phase-Oscillated Powder Layers
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Solution Overview
Problem
Conventional methods struggle to form high-strength metallic parts, such as steel plates, into desired shapes due to their thickness and strength, making it difficult to achieve complex geometries and efficient assembly.
Innovation Solution
A method involving the formation of multi-layered metallic parts by alternating ductile and high-strength powder layers, where the crystallographic phase of the powder layers is oscillated between austenite and ferrite/cementite phases, and consolidated using magnetic fields, allowing for the creation of complex shapes and enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength steel plates are made thick to withstand impacts, then strength and impact resistance are improved, but the difficulty of forming desired shapes increases
Solution Approach 1:
The armor plate is divided into multiple alternating layers of ductile material and high-strength powder material. Each layer has a thickness of 0.5-5 mm, creating a composite structure that combines the formability of ductile materials with the strength of high-strength materials. This segmentation allows the overall structure to achieve high impact resistance while maintaining ease of forming through the ductile layers.
Solution Approach 2:
The invention creates a composite material structure by alternating ductile layers and high-strength powder layers. The ductile layers provide formability and ductility, while the high-strength powder layers provide strength and hardness. The composite structure achieves both high strength and good formability that cannot be obtained with single-material thick plates.
2Device complexity
If conventional methods are used to form high-strength metallic parts, then manufacturing simplicity is maintained, but the ability to create complex geometries is limited
Solution Approach 1:
By dividing the part into multiple thin alternating layers, the structure can be formed more easily than a single thick high-strength part. The ductile layers can be formed into complex geometries using conventional forming methods, while the powder layers are consolidated between them, enabling complex overall geometries with manufacturing simplicity.
Solution Approach 2:
The invention changes the physical state of the powder material through phase oscillation during consolidation. By oscillating the crystallographic phase between austenite and ferrite/cementite, the powder material transforms into a consolidated form that fits between the ductile layers, enabling complex geometries to be achieved.
3Strength
If high-strength powder layers are used in the multi-layered assembly, then overall strength is improved, but the ductility of the material decreases
Solution Approach 1:
The material is segmented into alternating layers where ductile layers and high-strength powder layers each perform their specialized function. The ductile layers maintain overall ductility and formability of the assembly, while the high-strength powder layers provide localized strength enhancement. This segmentation resolves the contradiction by distributing functions across different layers.
Solution Approach 2:
The composite structure combines materials with complementary properties - ductile material providing formability and high-strength powder material providing strength. The alternating layer configuration ensures that the overall assembly benefits from both ductility and strength, resolving the trade-off between these properties.
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
This approach enables the formation of multi-layered metallic parts with improved strength and ability to withstand impacts, facilitating the creation of complex geometries and efficient assembly, particularly suitable for armor applications.
Implementation Method 1
applying a magnetic field to the at least one high-strength powder layer to increase the phase transformation temperature
Implementation Method 2
oscillating a crystallographic phase of the powdered metallic material of the at least one high-strength powder layer between a first crystallographic phase and a second crystallographic phase
Data Source
AI summary
Disclosed herein is a method of forming a multi-layered metallic part. The method comprises forming a plurality of ductile layers made of a metallic material having a first ductility. The method also comprises forming at least one high-strength powder layer made of a powdered metallic material having a second ductility higher than the first ductility. The method further comprises assembling the plurality of ductile layers and the at least one high-strength powder layer in an alternating and stacked formation to form a multi-layered metallic assembly. The method additionally comprises oscillating a crystallographic phase of the powdered metallic material of the at least one high-strength powder layer between a first crystallographic phase and a second crystallographic phase.