Bechtel Bwxt Idaho, Lcc

The United States As Represented by the United States Department of

Dominic J Varacalle, Jr

Timothy D Burchell

Henry S Chu

Herbert Herman

Gary C Strempek

H Alan Bruck

A lightweight armor system may comprise a substrate having a graded metal matrix composite layer formed thereon by thermal spray deposition. The graded metal matrix composite layer comprises an increasing volume fraction of ceramic particles imbedded in a decreasing volume fraction of a metal matrix as a function of a thickness of the graded metal matrix composite layer. A ceramic impact layer is affixed to the graded metal matrix composite layer.

Lightweight armor system and process for producing the same

The vacuum plasma spray process produces well-bonded, dense, stress-free coatings for a variety of materials on a wide range of substrates. The process is used in many industries to provide for the excellent wear, corrosion resistance, and high temperature behavior of the fabricated coatings. In this application, silicon metal is deposited on graphite. This invention discloses the optimum processing parameters for as-sprayed coating qualities. The method also discloses the effect of thermal cycling on silicon samples in an inert helium atmosphere at about 1600.degree.C. which transforms the coating to silicon carbide.

Method of fabricating silicon carbide coatings on graphite surfaces

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Idaho Falls, ID, United States of America

Dominic J Varacalle, Jr