A Novel Manufacturing Processing Route for Forming High-Density Ceramic Armor Materials: Phase I - SBIR

Report No. ARL-CR-437
Authors: Raman, Ramas V.
Date/Pages: April 1999; 48 pages
Abstract: The objective of the Phase I small business innovative research (SBIR) project was to demonstrate the feasibility of applying the Combustion Synthesis (CS)/Ceracon Consolidation Process for forming 10-cm-diameter, 2.5-cm- thick high-density titanium carbide (TiC) and titanium diboride (TiB2) pieces. The Phase I project demonstrated for the first time the feasibility of CS initiation to form TiC and TiB2 by using Ceracon's hot, granular media and their in-situ consolidation. The effects of applied pressure and pressure-transmitting media (PTM) temperature in controlling density, as well as thermal management issues to prevent cracking in applying the CS/Ceracon process to form TiC and TiB2, have been identified. In-situ CS/Ceracon consolidation to densities exceeding 98% was demonstrated for fabricating 10-cm-diameter, 2.5-cm-thick TiC pieces. The CS/Ceracon-processed, high-density TiC specimen has a fine grain size, microhardness values exceeding 2,500 kg/mm2, and compressive strength of 1.3 GPa. Due to the use of inexpensive conventional forging equipment and a low- cost grain for both initiating self-propagating high-temperature synthesis (SHS) and consolidation, this novel approach has the potential to be significantly more cost effective than currently used conventional hot pressing (HP) or hot isostatic pressing (HiPing) of TiC and TiB2 powders. A set of recommendations for the technical approach to be followed in process upscaling in Phase II to fabricate larger size tiles of TiC material is provided.
Distribution: Approved for public release
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Last Update / Reviewed: April 1, 1999