Encapsulated ceramic armor

Abstract

An impact resistant clad composite armor which includes a ceramic core, and a layer of bulk amorphous alloy surrounding the ceramic core and preferably bonded chemically to the ceramic core and a method of manufacturing such armor is provided.

What is claimed is: 
     
       1. A method of manufacturing a ceramic armor comprising:
 providing a ceramic core; 
 providing a quantity of a molten amorphous alloy, said amorphous alloy having a yield strength of at least 1.6 GPa and an elastic strain limit of at last 1.2%; and 
 forming a metallic layer encapsulating said ceramic core from the amorphous alloy such that the metallic layer places the ceramic core under a compressive stress of at least 400 MPa, wherein at least a portion of the metallic layer formed from the amorphous alloy has a thickness of about 0.5 mm or more. 
 
     
     
       2. The method as described in  claim 1 , wherein the amorphous alloy is described by the following molecular formula: (Zr,Ti) a (Ni,Cu,Fe) b (Be,Al,Si,B) c , wherein “a” is in the range of from about 30 to 75, “b” is in the range of from about 5 to 60, and “c” in the range of from about 0 to 50 in atomic percentages. 
     
     
       3. The method as described in  claim 1 , wherein the amorphous alloy is described by the following molecular formula: (Zr,Ti) a (Ni,Cu) b (Be) c , wherein “a” is in the range of from about 40 to 75, “b” is in the range of from about 5 to 50, and “c” in the range of from about 5 to 50 in atomic percentages. 
     
     
       4. The method as described in  claim 1 , wherein the amorphous alloy is described by the following molecular formula: (Zr,Ti) a (Ni,Cu) b (Be) c , wherein “a” is in the range of from about 45 to 65, “b” is in the range of from about 7.5 to 35, and “c” in the range of from about 10 to 37.5 in atomic percentages. 
     
     
       5. The method as described in  claim 1 , wherein the amorphous alloy is described by the following molecular formula: (Zr) a (Nb,Ti) b (Ni,Cu) c (Al) d , wherein “a” is in the range of from about 45 to 65, “b” is in the range of from about 0 to 10, “c” in the range of from about 20 to 40, and “d” in the range of from about 7.5 to 15 in atomic percentages. 
     
     
       6. The method as described in  claim 1 , wherein the amorphous alloy is based on ferrous metals wherein the elastic limit of the amorphous alloy is about 1.2% and higher, and the hardness of the amorphous alloys is about 7.5 Gpa and higher. 
     
     
       7. The method as described in  claim 1 , wherein the amorphous alloy is described by a molecular formula selected from the group consisting of: Fe 72 Al 5 Ga 2 P 11 C 6 B 4  and Fe 72 Al 7 Zr 10 Mo 5 W 2 B 15 . 
     
     
       8. The method as described in  claim 1 , wherein the amorphous alloy further comprises a ductile metallic crystalline phase precipitate. 
     
     
       9. The method as described in  claim 1 , wherein the step of forming comprises casting the metallic layer around the ceramic core. 
     
     
       10. The method as described in  claim 9 , wherein the method of casting is selected from the group consisting of as permanent mold casting, counter gravity casting and die-casting. 
     
     
       11. The method as described in  claim 1 , wherein the step of forming comprises molding the metallic layer around the ceramic core. 
     
     
       12. The method as described in  claim 11 , wherein the method of molding is selected from the group consisting of blow molding, die-forming, and replication die molding. 
     
     
       13. The method as described in  claim 1 , wherein the step of forming includes providing sufficient temperature to ensure chemical bonding between the metallic layer and the ceramic core. 
     
     
       14. The method as described in  claim 1 , wherein the metallic outer layer is formed at a substantially uniform thickness around the ceramic core. 
     
     
       15. The method as described in  claim 1 , wherein the metallic layer applies a compressive stress of 800 MPa or more to the ceramic core. 
     
     
       16. A composite comprising a ceramic core and a metallic layer comprising an amorphous alloy, said amorphous alloy having a yield strength of at least 1.6 GPa and an elastic strain limit of at least 1.2%; wherein the metallic layer at least partially encapsulates said ceramic core such that the metallic layer places the ceramic core under a compressive stress of at least 400 Mpa, wherein at least a portion of the metallic layer has a thickness of about 0.5 mm or more.  
     
     
       17. The composite as described in claim 16, wherein the amorphous alloy is described by the following molecular formula: (Zr,Ti) a (Ni,Cu,Fe) b (Be,Al,Si,B) c , wherein “a” is in the range of from about 30 to 75, “b” is in the range of from about 5 to 60, and “c” in the range of from about 0 to 50 in atomic percentages.  
     
     
       18. The composite as described in claim 16, wherein the amorphous alloy is described by the following molecular formula: (Zr,Ti) a (Ni,Cu) b (Be) c , wherein “a” is in the range of from about 40 to 75, “b” is in the range of from about 5 to 50, and “c” in the range of from about 5 to 50 in atomic percentages.  
     
     
       19. The composite as described in claim 16, wherein the amorphous alloy is described by the following molecular formula: (Zr,Ti) a (Ni,Cu) b (Be) c , wherein “a” is in the range of from about 45 to 65, “b” is in the range of from about 7.5 to 35, and “c” in the range of from about 10 to 37.5 in atomic percentages.  
     
     
       20. The composite as described in claim 16, wherein the amorphous alloy is described by the following molecular formula: (Zr) a (Nb,Ti) b (Ni,Cu) c (Al) d , wherein “a” is in the range of from about 45 to 65, “b” is in the range of from about 0 to 10, “c” in the range of from about 20 to 40, and “d” in the range of from about 7.5 to 15 in atomic percentages.  
     
     
       21. The composite as described in claim 16, wherein the amorphous alloy is based on ferrous metals wherein the elastic limit of the amorphous alloy is about 1.2% and higher, and the hardness of the amorphous alloys is about 7.5 Gpa and higher.  
     
     
       22. The composite as described in claim 16, wherein the amorphous alloy comprises FeAlGaPCB.  
     
     
       23. The composite as described in claim 16, wherein the amorphous alloy comprises FeAlZrMoWB.  
     
     
       24. The composite as described in claim 16, wherein the amorphous alloy further comprises a ductile metallic crystalline phase precipitate.  
     
     
       25. The composite as described in claim 16, wherein the metallic layer is formed at a substantially uniform thickness around the ceramic core.  
     
     
       26. The composite as described in claim 16, wherein the metallic layer applies a compressive stress of 800 MPa or more to the ceramic core.