Surface Treatment Technologies, Inc.

W Mark Buchta

Timothy J Langan

Michael A Riley

David M Otterson

The present invention relates to reactive materials formed by thermal spray techniques. The thermally sprayed reactive materials have low porosity and high structural integrity. The reactive materials are useful for applications such as shaped charges, thermite welding, near net shaped components and the like.

Reactive materials and thermal spray methods of making same

Metal aluminides are formed by an initial thermal deposition process which forms an intermediary material comprising elemental aluminum and another elemental metal, as well as an oxide of the other metal. The thermally formed intermediary material is subsequently heated to initiate an exothermic reaction which forms the metal aluminide material. The reaction may be initiated by localized or bulk heating of the intermediary material, and may involve reaction between the aluminum and elemental metal as well as a thermite reaction between the aluminum and the metal oxide. The resultant metal aluminide material may be substantially fully dense and may contain oxide strengthening precipitates such as aluminum oxide.

Thermal deposition of reactive metal oxide/aluminum layers and dispersion strengthened aluminides made therefrom

Shaped charge liners are made of reactive materials formed by thermal spray techniques. The thermally sprayed reactive shaped charge materials have low porosity and high structural integrity. Upon detonation, the reactive materials of the shaped charge liner undergo an exothermic reaction that raises the temperature and the effectiveness of the liner.

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Ellicott City, MD, United States of America

W Mark Buchta