Lockheed Martin Corporation

Craig A Brice

Brian Taylor Rosenberger

Slade H Gardner

Frederick James Herman

Nathan L Weber

Bill Capshaw

Brian T Rosenberger

Nathan L Webber

A direct manufacturing technique involving rapid solidification processing uses a reaction between a metallic molten pool and a reactant gas in an inert atmosphere to form alloys with improved desired properties. By utilizing rapid solidification techniques, solubility levels are increased resulting in alloys with unique mechanical and physical properties. Laser deposition of alloys in atmospheres of varying reactant content produce compositions with intermingled and significantly improved overall properties.

Co-continuous metal-metal matrix composite material using timed deposition processing

A variable hardness gradient armor alloy is produced with a liquid-state reaction between a metallic molten pool and a gaseous atmosphere having a small fraction of reactive gas. The content of the reactant gas is varied as the armor is fabricated in order to vary the properties of the resultant material across its thickness and typically include, for example, a hardened outer or initial layer for impact resistance, and at least one inner layer having a lower hardness than the outer layer but greater energy absorption.

System, method, and apparatus for variable hardness gradient armor alloys

A solid state method for the preparation of composite materials incorporating metal and nano materials is provided, wherein nano materials are deposited on a substrate and incorporated into the substrate structure by friction stir welding. Also provided are composite materials that include nano materials, which are prepared by friction stir welding.

Metal matrix carbon nanotube composite material and method of making same

Ring-shaped shape memory alloys put disk-shaped ceramic materials in a state of compression. The rings are radially deformed to introduce plastic strain into the rings. The rings are sized to closely receive the disk-shaped ceramic strike plates. When the assembly is heated, the rings attempt to regain their original shape and thereby put the ceramic strike plates into uniform, two-dimensional compression.

System, method, and apparatus for improving the performance of ceramic armor materials with shape memory alloys

Leading edge structures for high performance aircraft and the direct manufacture thereof are disclosed. Direct manufacturing technology is used to deposit leading edge structures directly from a digital model to form near-net shape products. This technique permits a wider range of materials to be utilized, such as casting alloys capable of the highest temperature usage that are not available in billet or sheet form. Refractory metals or high temperature ceramics also may be used to form the entire lead edge structure, or just a replaceable tip of the leading edge structure.

System, method, and apparatus for leading edge structures and direct manufacturing thereof

A ballistic armor uses shape memory alloys and novel joining techniques to form a solution from a combination of shape memory metallic alloys (SMA) and ceramic materials. The SMA allows a high amount of strain to be recovered through a low temperature heat treatment. The amount of strain recoverable is much higher than that available through conventional thermal expansion mismatch solutions. Solid state or low temperature bonding methods are used to join the dissimilar materials. This joining technique avoids introducing excessive heat that would cause the SMA to transform before the armor system is assembled.

System, method, and apparatus for forming ballistic armor from ceramic and shape memory metallic alloy materials

A system for fabricating a free form structure of a composite material including carbon nanotubes. The system includes a discharge assembly and a composite formation device operatively linked with the discharge assembly. The discharge assembly dispenses a fusing agent such as for example a high energy density emission, a laser emission or a particle beam emission. The composite formation device includes a composite generator and an arranger in operative engagement with a composite generator. The composite generator engages with the fusing agent so as to create a composite nodal element. The composite nodal element includes a matrix and a multiplicity of fibers formed of carbon nanotubes dispersed throughout the matrix. The arranger positions one node relative to another to define the free form structure.

Rapid manufacturing of carbon nanotube composite structures

An alloy of aluminum, lithium, magnesium, zirconium, and scandium is formed with a rapid solidification process to retain desired metastable phases. A solid freeform fabrication device uses a heat source to melt a feedstock delivered through one or more guide nozzles. The heat source and the nozzles are mounted to a movable platform that positions the heat source and the nozzles in a desired location for each section or layer of the part being formed. The nozzles are located at 90&#xb0; increments in an array having a selected radius from, and being centered on the heat source. The device forms adjacent, side-by-side layers to form the width of the part, and is used to form adjacent, stacked layers to create the height of the part.

High strength aluminum alloy and method of producing same

A single-crystal structure is grown using free-form fabrication through principles of directional solidification and direct-deposition techniques. The structure is formed from a metallic alloy by building from feedstock on top of and upward from a heated base element. The top of the structure is also heated with a scanning beam as it is built. The higher temperatures near the melting alloy tend to promote crystal growth rather than nucleation as the grain grows toward the heat of the scanning beam. This allows a two-dimensional thermal gradient to be formed in the build direction, which allows the solid crystal to maintain one orientation during the deposition process. As the material initially solidifies, it nucleates off of a desired grain that is designated by a grain selector. This method eliminates the need for expensive mold cavities and segmented furnaces that are typically required by prior art processes for producing some components.

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Keller, TX, United States of America

Craig A Brice