Multi-structure metal matrix composite armor with integrally cast holes

摘要

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.