Compositionally-graded metal-ceramic structure and method for manufacturing the same

Abstract

A compositionally-graded structure including a body having a first major surface and a second major surface opposed from the first major surface along a thickness axis, the body including a metallic component and a ceramic component, wherein a concentration of the ceramic component in the body is a function of location within the body along the thickness axis, wherein transitions of the concentration of the ceramic component in the body are continuous such that distinct interfaces are not macroscopically established within the body, and wherein the concentration of the ceramic component is at least 95 percent by volume at at least one location within the body along the thickness axis.

What is claimed is: 
     
         1 . A compositionally-graded structure comprising:
 a body having a first major surface and a second major surface opposed from said first major surface along a thickness axis, said body comprising a metallic component and a ceramic component,   wherein a concentration of said ceramic component in said body is a function of location within said body along said thickness axis,   wherein transitions of said concentration of said ceramic component in said body are continuous such that distinct interfaces are not macroscopically established within said body, and   wherein said concentration of said ceramic component is at least 95 percent by volume at at least one location within said body along said thickness axis.   
     
     
         2 . The compositionally-graded structure of  claim 1  wherein said metallic component comprises a titanium alloy. 
     
     
         3 . The compositionally-graded structure of  claim 2  wherein said ceramic component comprises titanium diboride. 
     
     
         4 . The compositionally-graded structure of  claim 3  wherein said body further comprises titanium boride. 
     
     
         5 . The compositionally-graded structure of  claim 2  wherein said ceramic component comprises titanium carbide. 
     
     
         6 . The compositionally-graded structure of  claim 1  wherein said metallic component comprises a metal element, and wherein said ceramic component also comprises said metal element. 
     
     
         7 . The compositionally-graded structure of  claim 1  wherein said function is substantially linear. 
     
     
         8 . The compositionally-graded structure of  claim 1  wherein said function is non-linear. 
     
     
         9 . The compositionally-graded structure of  claim 1  wherein said concentration of said ceramic component is about 100 percent by volume at at least one location within said body along said thickness axis. 
     
     
         10 . The compositionally-graded structure of  claim 1  wherein said concentration of said ceramic component is at least 95 percent by volume proximate said first major surface. 
     
     
         11 . The compositionally-graded structure of  claim 10  wherein said concentration of said ceramic component is at most 20 percent by volume proximate said second major surface. 
     
     
         12 . The compositionally-graded structure of  claim 10  wherein said concentration of said ceramic component is at most 10 percent by volume proximate said second major surface. 
     
     
         13 . The compositionally-graded structure of  claim 10  wherein said concentration of said ceramic component is about 0 percent by volume proximate said second major surface. 
     
     
         14 . The compositionally-graded structure of  claim 1  wherein:
 said concentration of said ceramic component is at least 95 percent by volume proximate said first major surface; and 
 a concentration of said metallic component is at least 80 percent by volume proximate said second major surface. 
 
     
     
         15 . An armor panel comprising:
 a compositionally-graded structure comprising:
 a body having a first major surface and a second major surface opposed from said first major surface along a thickness axis, said body comprising a metallic component and a ceramic component, 
 wherein a concentration of said ceramic component in said body is a function of location within said body along said thickness axis, 
 wherein transitions of said concentration of said ceramic component in said body are continuous such that distinct interfaces are not macroscopically established within said body, and 
 wherein said concentration of said ceramic component is at least 95 percent by volume at at least one location within said body along said thickness axis; and 
   an anti-spalling layer adjacent to said second major surface of said body.   
     
     
         16 . The armor panel of  claim 15  wherein said anti-spalling layer comprises high-density polyethylene. 
     
     
         17 . A method for manufacturing a compositionally-graded structure comprising:
 assembling a powder layup comprising at least a first powdered material and a second powdered material, said first powdered material comprising a ceramic component and said second powdered material comprising a metallic component, said powder layup comprising:
 a first layer comprising a first concentration of said ceramic component; 
 a second layer comprising a second concentration of said ceramic component and a first concentration of said metallic component; and 
 a third layer comprising a third concentration of said ceramic component and a second concentration of said metallic component; 
   pressing said powder layup to yield a compact; and   heat treating said compact.   
     
     
         18 . The method of  claim 17  wherein said ceramic component comprises titanium diboride and said metallic component comprises a titanium alloy. 
     
     
         19 . The method of  claim 17  wherein said heat treating comprises hot isostatic pressing. 
     
     
         20 . The method of  claim 17  wherein said heat treating comprises hot pressing.