US Government As Represented by the Secretary of the Army

Allied Corporation

South Dakota Board of Regents

Deepak Kapoor

Tony F Zahrah

Roderick Rowland

Christopher D Haines

Chung-Chu Wan

Michael E Ellis

Steven C Lawver

Rong Y Wang

Zhihui Zhang

Enrique J Lavernia

Rajesh Shende

Lori J Groven

Jan Puszynski

John E Brough

Julie M Schoenung

Zac Doorenbos

Yizhang Zhou

Ying Li

Michael V Bruno

Joshua McGowan

Troy Topping

Rustin Vogt

Sergio Torrejon

Joseph Paras

James Grzybek

A method for preparing a composite projectile body with preformed fragments precisely embedded within the walls of the projectile body. The process utilizes a combination of additive manufacturing and advanced powder metallurgy fabrication techniques. Specifically a skeletal structure or prefabricated cage body is filled with preformed fragments. The cage structure may be situated on a mandrel or tool inside a container. The container is filled with metal powder, degassed under vacuum, and sealed. The canister is then subjected to heat and pressure to consolidate the powder to full density. The canister is then removed and the compacted billet product is further machined to obtain a desired projectile body.

Method of manufacturing composite projectile body embedded with preformed fragments

Process for making a fragmentation warhead using hot isostatic pressing where tungsten spheres, powdered steel, and interlock features on a mandrel are consolidated in a matrix. Then in the finished part, the front fragmentation cap, rear and interior geometries are machined, resulting in a finished warhead with an enhanced performance fragmentation cap integrally bonded to it.

Method for making a composite fragmentation cap that is integrally formed onto a projectile body

A non-faceted nanoparticle reinforced metal matrix composite having increased ductility, while maintaining strength. In particular, a non-faceted nanoparticle reinforced metal matrix composite is provided comprised of spherical or ellipsoidal shaped (non-faceted) nanoparticles comprising one or more of boron carbide, titanium diboride, silicon nitride, alumina and boron nitride, and a nanostructured matrix composite comprised of one or more metals and/or metal alloys. In addition, a method of manufacturing such a non-faceted nanoparticle reinforced metal matrix composite is provided.

Non-faceted nanoparticle reinforced metal matrix composite and method of manufacturing the same

An improved method for the production of pyrophoric materials which does not employ hot NaOH and produces pyrophoric materials on various types of ceramic, metal, nanomaterial substrates. The method impregnates the substrate materials with pyrophoric iron or other materials resulting in materials that are 'tunable' with respect to its pyrophoric output as determined by its temperature, rise time sustenance etc through selective variation of particle size, morphology, and diluents or reactive materials.

Pyrophoric materials and methods of making same

Disclosed is a flow-softening tungsten alloy having the general formula:wherein W is tungsten; A is one or more elements selected from the group consisting of nickel, iron, chromium and cobalt; B is in or more elements selected from the group consisting of molybdenum, niobium and tantalum; C is one or more of the elements selected from the groups consisting of titanium and aluminum; D is one or more elements selected from the group consisting of boron, carbon, and silicon; i is from about 5 to about 8 weight percent; j is from 0 to about 4 weight percent; k is from about 0.1 to about 4 weight percent; 1 is from 0 to about 0.1 weight percent; and p is greater than or equal to about 7 weight percent and less than or equal to about 20 weight percent. In this alloy p is approximately equal to the sum of i, j, k and 1. A method of preparing this alloy and a kinetic energy penetrator manufactured from it are also disclosed.

Tungsten alloys for penetrator application and method of making the same

A tungsten heavy alloy composition comprising tungsten, iron and elements selected from the groups X, Y and Z and having the formula W.sub.100-p Fe.sub.i X.sub.j Y.sub.k Z.sub.l. Such that 'X' is one or more elements selected from the group consisting of Ni, Mn and Co; 'Y' is one or more elements selected from the group consisting of Cr, Mo and V; 'Z' is one or more elements selected from the group consisting of C, Si, Ti and Al; 'i' ranges from 5 to 19.5 weight percent; 'j' ranges from 0.05 to 6 weight percent; 'k' ranges from 0.15 to 5 weight percent; 'l' ranges from 0.05 to 4 weight percent; and 'p' is the mathematical sum of i, j, k and l, and ranges from 7 to 20 such that '100-p' ranges from 93 to 80 weight percent. The blended powder mixture thus formed is hot consolidated to full density. The hot consolidated blended powder mixture is subjected to a hardening heat treatment. The WHA composition thus formed is adiabatically shearable with flow-softening characteristics resulting in a material with superior ballistic penetration characteristics. The process of forming the composition consists of first blending quantities of iron powder with elements X, Y and Z to form a matrix of the composition. Quantities of powdered tungsten and the matrix are then blended to form a blended powder mixture which is then hot consolidated to full density. The hot consolidation temperature is selected to achieve full density but less than the intermetallic phase formation temperature between tungsten and iron, i.e. 1050.degree. C. The preferred hot consolidation temperature is at or below 1000.degree. C. The hot consolidated blended powder mixture is then subjected to a hardening heat treatment to form an adiabatically shearable, flow-softening WHA composition which is therefore a predicted superior performing ballistic penetrating armor piercing core material.

Heat treatable tungsten alloys with improved ballistic performance and

Disclosed is a flow-softening tungsten alloy having the general formula:

Flow softening tungsten based composites

Tungsten heavy alloys comprising by weight from about 80 to about 100% tuten and from about 0 to about 20% of one or more heavy alloying metals are produced by introducing powders of tungsten and the alloying metals into a thermal spray plasma gun, melting the powders in the hot zone of the gun to form a molten alloy and then spraying the molten alloy in droplet form into a collecting chamber where the droplets are solidified, and the resultant alloy in powdered form is collected. The powdered alloy can be further mixed with powdered copper, iron, nickel, cobalt or tantalum and compacted by dynamic or explosive compaction to form a near full density material. Full density materials are produced by further thermomechanical processing of the compact.

Plasma spraying tungsten heavy alloys

Tungsten heavy alloys

A composite material comprising a metal matrix containing tungsten grain is roduced from tungsten powders formed by plasma rapid solidification. The powders comprise tungsten and up to 20 weight percent of a metal selected from the group consisting of molybdenum, tantalum, niobium, rhenium, and chromium. The surfaces of the powders are cleaned to reduce the surface oxide thereon, and the powders are coated with at least one metal selected from the group consisting of copper, nickel, cobalt, hafnium and tantalum. The coated powders are formed into a sintered preform which is less than fully dense, and the sintered preform is further consolidated to full density by a technique selected from hot isostatic pressing, rapid omin-directional compaction, and hot extrusion.

Methods are producing composite materials of metal matrix containing

A homogeneous boron containing alloy is disclosed with a composition which can be essentially represented by the formula of: M.sub.i T.sub.j B.sub.k where M is a metal from the group of nickel, iron, cobalt or a mixture thereof; T is a refractory metal from the group of molybdenum, tungsten, or a mixture thereof; and B is the element boron. The subscripts i, j, k are the respective atomic percent of each of the constituents and vary respectively between about 25 and 98, between about 1 and 40, and between 1 and 35 with the proviso that j&gt;k, and i+j+k=100. By further limitation of the chemistry, it is possible to assure the alloy will age harden.

Growing community of inventors

Rockaway, NJ, United States of America

Deepak Kapoor