Additively Manufactured Warhead Support Structure
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Solution Overview
Problem
Conventional warhead designs require a large proportion of supporting structure that does not contribute significantly to the effective mass, leading to inefficiencies in mechanical stability and payload capacity.
Innovation Solution
A support structure is created by integrating a heavy metal active mass with a base body using additive manufacturing, where the active mass is materially bonded to the base body, forming a monolithic component that absorbs mechanical loads and contributes to both stability and fragmentation effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large proportion of supporting structure is used to ensure mechanical stability, then the warhead can withstand firing and penetration loads, but the overall mass increases and payload capacity decreases
Solution Approach 1:
The invention merges the supporting structure and active mass into a single monolithic component through additive manufacturing. The base body and active mass are materially bonded to form an integrated structure where both components share mechanical loads, eliminating the need for separate supporting structures and reducing overall mass while maintaining strength
Solution Approach 2:
The invention uses composite construction by combining a base body material with a heavy metal active mass through additive manufacturing. This composite structure allows the active mass to contribute to both the mechanical strength and the desired mass for fragmentation, resolving the contradiction between structural strength and overall weight
2Strength
If conventional manufacturing methods are used to create supporting structures, then mechanical stability is achieved, but the base body must absorb all forces alone and cannot contribute to fragmentation
Solution Approach 1:
The invention combines the supporting structure and active mass into one monolithic component manufactured via additive manufacturing. This allows the active mass to structurally participate in force absorption during firing and penetration, while also being positioned to contribute to fragmentation effects, eliminating the need for separate components
Solution Approach 2:
The invention changes the manufacturing parameter from conventional subtraction-based methods to additive manufacturing. This enables the creation of complex monolithic structures with integrated active mass that would be difficult or impossible to achieve with traditional manufacturing, allowing both force absorption and fragmentation functionality
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 integration reduces the overall mass of the warhead, allowing for increased payload and improved mechanical stability, as both the base body and active mass share the load, enhancing the warhead's performance during firing and penetration.
Implementation Method 1
The active mass is materially attached to the base body and connected to it by means of a first additive manufacturing process
Implementation Method 2
the support structure forms one, in particular the only, mechanical basic structure of the warhead, which causes its mechanical stability and penetration resistance and which, in particular, absorbs the forces occurring on the warhead when the warhead is fired as intended
Data Source
Figure 1~2
AI summary
A support structure (2) for a warhead (4) comprises a base body (6) made of a structural material and an active material (16) made of a heavy metal, wherein the base body (6) is configured to accommodate or be connected to further components of the warhead (4), and wherein the active material (16) is bonded to the base body (6) by a first additive manufacturing process. A warhead (4) comprises the support structure (2). In a process for manufacturing the support structure (2), the base body (6) is provided and the active material (16) is bonded to the base body (6) by the first additive manufacturing process. In a process for manufacturing the warhead (4), its support structure (2) is manufactured according to the aforementioned process.