SBIR-STTR Award

Ceramics and ceramic matrix composite are used as advanced armor materials for their lightweight and superior ballistic performance. The silicon carbide (SiC) armor material, processed by hot pressing at temperature >2000 ?C under high pressure for several hours has better ballistic performance compared to material by other processing routes. However, hot pressing is a slow batch process. Currently semi-continuous Pressure Assisted Densification (PAD) method for SiC material is under development for increasing the yield. The PAD process alone cannot meet the near future demand for ballistic grade SiC. Thus there is a need for alternate continuous processing approaches that have potential for high yields. We propose to develop a Dynamic Processing method for SiC material where high green bodies close to full density are produced in sub-millisecond compaction durations that will enable lower sintering temperature-duration cycles. Due to high green density, the special microstructures and grain sizes of the powders will be retained after sintering to yield high ballistic performance. The proposed dynamic processing method that combines fast compaction with a short sintering cycle has the potential to be developed into a continuous processing method to deliver high performance and high yield

In proposed Phase II project IAP will develop a high rate, cost effective manufacturing method for producing silicon carbide (SiC) tiles via combination of high density Dynamic Magnetic Compaction (DMC) for near net shape green body forming and Pressure-less Sintering (PS) for full density sintered body. This manufacturing method is referred to as DMC PS SiC process. The objective of the Phase II effort is to develop DMC process to produce 4îx 4î tiles for ballistic tests. In addition, based on Phase I results, and Phase II optimization steps, DMC PS SiC processing will be studied with a cost model for implementing in a semi-continuous manufacturing mode for high rate production with increased capacity in Phase III.

Keywords:
Silicon Carbide, Armor Tiles, Dmc, Pressure Less Sintering, Dmc Ps Sic, Ballistic Protection