Multi-structure metal matrix composite armor with integrally cast holes

Abstract

A lightweight armor system according to the present invention includes one or more material layers having a fraction of void volume and at least one of those material layers having holes of various sizes and designs integrated therein. The material layers are infiltrated with liquid metal which solidifies within the materials open porosity to bind the layers together to create a coherent integral structure. The holes may be in the form of tubes which are impervious to metal infiltration and reduce the weight of the armor system while contributing to projectile deflection. A process for producing a lightweight armor system is disclosed which comprises the steps of 1.) forming holes in a preform containment layer 2.) positioning sealed tubes in the formed holes so that the tubes run through the thickness of the preform 3.) positioning at least one preform w/ sealed tubes within a mold chamber of a closed mold and 4.) infiltrating the mold with a liquid metal.

1 . An integrated layered armor, comprising:
 A plurality of layers comprising:   at least one dense layer and at least one containment layer,   at least one of said at least one containment layer comprising a plurality of holes integrated therein, said at least one containment layer and said at least one dense layer having a fraction of void volume prior to metal infiltration, said at least one containment layer and said at least one dense layer further comprising a metal, said metal infiltrated within said void volumes of said of least one containment layer and said at least one dense layer, said plurality of holes not infiltrated with said metal,   said metal infiltration binding said plurality of layers together to form an integrated structure by infiltrating said void volumes of said plurality of containment layers and said void volume of said dense layers, encapsulating said plurality of layers to form an integrated layered armor in the desired product shape geometry.   
     
     
         2 . An integrated layered armor as in  claim 1 , further including at least one metal enveloping layer, said metal enveloping layer encapsulating said at least one containment layer and said at least one dense layer. 
     
     
         3 . An integrated layered armor as in  claim 1 , wherein said containment layer fraction of void volume prior to metal infiltration is between about 30% and about 98%. 
     
     
         4 . An integrated layered armor as in  claim 1 , wherein said surface void volume of said at least one dense layer prior to metal infiltration is 20% or less, said at least one dense layer having no interconnected porosity which would provide a path for metal infiltration from the surface to the interior of said at least one dense layer. 
     
     
         5 . An integrated layered armor as in  claim 1 , wherein said at least one containment layers comprises a reinforcement material of ceramic, glass, or glass-ceramic, including oxides and non-oxides, selected from the group consisting of silicon carbide, aluminum oxide, silicates, boron-carbide, graphite and carbon, and in the form of particles, flakes, continuous and discontinuous fibers. 
     
     
         6 . An integrated layered armor as in  claim 1 , wherein said at least one of said at least one containment layers comprises a plurality of holes having a density between 20 and 80 percent. 
     
     
         7 . An integrated layered armor as in  claim 1 , wherein said at least one containment layers comprises a metal reinforcement. 
     
     
         8 . An integrated layered armor as in  claim 1 , wherein at least one of said at least one dense layer comprises a ceramic material selected from the group consisting of aluminum oxide, silicon carbide, boron carbide, silicon nitride and chemical vapor deposit diamond. 
     
     
         9 . An integrated layered armor as in  claim 8 , wherein said at least one of said at least one dense layer is a least 0.25 mm thick. 
     
     
         10 . An integrated layered armor as in  claim 1 , wherein at least one of said at least one dense layer comprises a metal material selected from the group consisting of titanium, tungsten, molybdenum, and depleted uranium. 
     
     
         11 . An integrated layered armor as in  claim 2  wherein said metal infiltrant and said metal enveloping layer are selected from the group consisting of aluminum alloys, copper, titanium, and magnesium. 
     
     
         12 . An integrated layered armor as in  claim 1 , wherein said plurality of holes includes metal or ceramic tubes integrated therein. 
     
     
         13 . An integrated layered armor as in  claim 12 , wherein said tubes are sealed. 
     
     
         14 . An integrated layered armor as in  claim 1 , wherein said plurality of holes are set in obliquity. 
     
     
         15 . An integrated layered armor as in  claim 1 , wherein said plurality of holes range from about 1/16 inch to about 1 inch in diameter. 
     
     
         16 . An integrated layered armor as in  claim 1 , wherein said plurality of holes in at least one of said containment layers is offset from said plurality of holes in another containment layer. 
     
     
         17 . An integrated layered armor as in  claim 12 , wherein said metal tube includes a reinforcement material therein. 
     
     
         18 . An integrated layered armor as in  claim 1 , wherein said plurality of holes integrated within said containment layer, are aligned horizontally. 
     
     
         19 . An integrated layered armor as in  claim 1 , wherein said plurality of holes integrated within said containment layer, are aligned vertically. 
     
     
         20 . An integrated layered armor as in  claim 1 , wherein said plurality of holes run through the entire length of said at least one of said at least one containment layer. 
     
     
         21 . A method of producing an armor plate comprising the steps of:
 Forming a plurality of holes in a reinforcement material layer;   Positioning sealed hollow tubes in said plurality of holes;   Placing said reinforcement material layer including said hollow tubes in a sealed mold cavity suitable for infiltration casting; and   Infiltrating under pressure said sealed mold cavity with liquid metal.)   
     
     
         22 . A method as in  claim 21 , further comprising prior to the step of infiltrating said sealed mold cavity, the step of :
 Placing at least one dense material layer in said sealed mold cavity.)   
     
     
         23 . A method as in  claim 21 , further comprising prior to the step of infiltrating said sealed mold cavity, the step of:
 Placing at least one containment material layer in said sealed mold cavity.)   
     
     
         24 . A method as in  claim 21 , including after the step of infiltrating said mold cavity with a liquid metal, the steps of:
 Cooling said armor plate until said metal infiltrant solidifies, and   Removing said armor plate from said sealed mold cavity.)   
     
     
         25 . An armor, comprising:
 at least one containment layer, at least one of said at least one containment layer comprising a plurality of sealed tubes integrated therein, said at least one containment layer having a fraction of void volume prior to metal infiltration, said at least one containment layer further comprising a metal, said metal infiltrated within said void volumes of said at least one containment layer, said sealed tubes not infiltrated with said metal.)   
     
     
         26 . An integrated layered armor as in  claim 25 , further including at least one metal enveloping layer, said metal enveloping layer encapsulating said at least one containment layer.) 
     
     
         27 . An integrated layered armor as in  claim 25 , wherein said containment layer comprises a discontinuous fiber material reinforcement perform.) 
     
     
         28 . An integrated layered armor as in  claim 27 , wherein said discontinuous fiber material comprises discontinuous fibers at a length of about 0.02 to about 4 inches.) 
     
     
         29 . An integrated layered armor as in  claim 27 , wherein said discontinuous fiber material has a volume of about 2 percent or more.) 
     
     
         30 . An integrated layered armor as in  claim 1 , wherein said at least one dense layer has zero void volume, said dense layer not infiltrated with metal.