Squeeze-Cast Metal Matrix Ceramic Composite for Impact Resistance

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Solution Overview

Problem

Current metal matrix ceramic composites face challenges in manufacturing complexity, high production costs, and insufficient ceramic restriction, limiting their performance and widespread application in security fields like safes and vault gates.

Innovation Solution

A metal matrix ceramic composite is formed through squeeze-casting, where ceramic granules with diameters between 1 mm and 15 mm are permeated with molten metal, creating a multilayer structure within a 10%-80% volume range, allowing for real three-dimensional restriction and improved mechanical and thermal properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If metal matrix ceramic composites are prepared by powder metallurgy, then the composite structure is achieved, but the manufacturing process becomes complex and production cost increases

Engineering Contradiction:

Improvecomposite structureVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent changes the manufacturing method from powder metallurgy to squeeze-casting, fundamentally altering the process parameters and steps involved. This substitution simplifies the manufacturing process while maintaining the composite structure, directly resolving the contradiction between achieving reliable composite structure and avoiding complex manufacturing processes

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the complex powder metallurgy mechanical system with a simpler squeeze-casting system. By substituting the multi-step powder metallurgy process with a single-step squeeze-casting process, the manufacturing complexity is reduced while the composite structure is still achieved through the infiltration of molten metal into ceramic granules

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If non-metal material bonding or mechanical connection is used to connect ceramic granules, then the composite is formed, but the restriction on ceramics from metal is insufficient leading to low overall performance

Engineering Contradiction:

Improveoverall performanceVSAvoidceramic restriction

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent creates a true metal matrix ceramic composite where molten metal infiltrates and bonds with ceramic granules at the molecular level. This composite structure provides superior metal restriction on ceramics compared to non-metal bonding or mechanical connection, as the metal-ceramic interface achieves strong adhesion through infiltration, directly resolving the contradiction between forming the composite and achieving sufficient ceramic restriction for high overall performance

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If ceramics are used as protective material, then light weight and inexpensive price are achieved, but brittleness causes cracking and collapsing under impact

Engineering Contradiction:

ImproveweightVSAvoidimpact resistance

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent creates a metal matrix ceramic composite that combines the light weight advantage of ceramics with the toughness of metal. The metal matrix provides a ductile framework that prevents crack propagation and supports the brittle ceramic granules under impact, resolving the contradiction between utilizing ceramic light weight and achieving sufficient impact resistance

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different material properties to different parts of the composite structure. Ceramic granules provide local hardness and light weight, while the metal matrix provides local toughness and impact resistance. This local quality differentiation allows the composite to simultaneously achieve light weight and high impact resistance

Inventive Principle:

Principle #3Local quality

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 method simplifies the manufacturing process, reduces costs, and enhances the composite's performance in resistance to impact, flame cutting, and bullet-proofing, with the ability to withstand oxyacetylene cutting for over 30 minutes and provide high protection coefficients against armor-piercing bullets.

Implementation Method 1

at least part of a matrix metal is permeated into an array of ceramic granules by means of squeeze-casting

Methodology Applied

Scientific EffectPermeation: Permeation

Implementation Method 2

squeeze-casting

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentUS9212413B2Metal matrix ceramic composite and manufacturing method and application thereof

Publication Date: 2015.12.15 CHINA WEAPON SCI ACADEMY NINGBO BRANCH

AI summary

A metal matrix ceramic composite is completely formed by permeating at least part of a matrix metal into an array of ceramic granules by squeeze-casting, and the volume percentage of the ceramic granules may be adjusted within a range of 10%-80% of the metal matrix ceramic composite according to the usage requirements. The metal matrix ceramic composites not only retain high performance of anti-penetration, but also have the strong toughness of the metal; in addition, this composite has features of low density, resistance against ordinary mechanical cutting and flame cutting, and inhibition of crack propagation and the like. The composite has broad application prospects in the protection of such important security facilities as safes, automatic teller machines and vault gates.