Nano-composite IR Window for Hypersonic Optical Guidance
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Solution Overview
Problem
Current materials for optical guidance systems in armaments, such as sapphire, face limitations in strength, thermal shock resistance, and processability, especially at hypersonic speeds, and existing alternatives have issues with sensitivity to water droplet impact and cost-effective manufacturing.
Innovation Solution
Development of a transparent nano-composite material comprising a matrix with nano-dispersoid particles less than 100 nm in size, produced through methods involving blending precursor powders, pressing, heating, and sintering under hot isostatic pressure, with techniques like sol-gel coating and polymer impregnation to enhance strength and transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sapphire is used for protective windows, then impact resistance and transparency are improved, but strength at high temperature deteriorates
Solution Approach 1:
The patent uses a composite material system consisting of spinel matrix combined with transparent ceramic phases (such as alumina, magnesia, or silica). This composite approach allows the material to maintain the high-temperature strength characteristics of spinel while incorporating the transparency and optical properties of the ceramic phases, thereby resolving the contradiction between impact resistance and high-temperature strength.
2Reliability
If single crystal sapphire is used, then transparency and impact resistance are improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent changes the manufacturing parameters by using polycrystalline spinel instead of single crystal sapphire, and employs ceramic processing techniques such as sintering, hot pressing, or slip casting. These parameter changes enable near-net-shape manufacturing with significantly reduced cost and complexity while maintaining the required optical and mechanical properties through careful control of grain size and phase composition.
3Ease of manufacture
If traditional window materials are used, then manufacturing is easier, but sensitivity to water droplet impact increases
Solution Approach 1:
The patent employs a spinel-based composite material that combines the ease of processing characteristic of spinel ceramics with enhanced resistance to water droplet impact. The composite structure, potentially incorporating nano-scale reinforcements or specific phase distributions, provides improved mechanical toughness and resistance to hypersonic water ingestion while maintaining manufacturability through conventional ceramic processing techniques.
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 nano-composite material provides enhanced strength, thermal shock resistance, and cost-effective manufacturing, maintaining transparency and impact resistance necessary for hypersonic applications, while minimizing light scatter and oxidation sensitivity.
Implementation Method 1
maintaining transparency and impact resistance necessary for hypersonic applications, while minimizing light scatter
Implementation Method 2
sintering the bisque-fired shape in a press to form a final structure
Implementation Method 3
sintered under hot isostatic pressure to form a final structure
Data Source
AI summary
A transparent, nano-composite material and methods for making structures from this material are provided. In one embodiment, the material is made from a polycrystalline matrix containing dispersed particles of a harder material. The particles are less then about 100 nm. In other embodiments, methods for making structures from the material are provided. In one aspect, the methods include blending precursor powders for the matrix and reinforcing phases prior to forming and sintering to make a final structure. In other aspects, a precursor powder for the matrix is pressed into a green shape, which is partially sintered and exposed to a solution containing a precursor for the reinforcing phase, prior to be sintered into the final material. In another aspect, the precursor powder for the matrix is coated with a sol-gel precursor for the reinforcing material, then pressed into a green shape and sintered to form the final structure.